Skip to main content

Archive

Show more

Cummins Engineer Trent Berardi Was In Trouble



Cummins engineer Trent Berardi was in trouble. Usually frigid Fargo, North Dakota (U.S.A.), was too warm.

With his team ready for two-and-a-half weeks of testing CumminsX12 engine under extreme winter conditions, Berardi had to quickly find cold temperatures close enough to his base in Columbus, Indiana (U.S.A.), to stay on time and budget. Then he got the good news: Idaho Falls, Idaho (U.S.A.), was having a cold snap.

Thankfully, we found the temperatures we were looking for relatively nearby,Berardi recalled.

Such is the life of a validation engineer, the last line of defense before a Cummins product like generator set reaches the customer.

These engineers oversee final testing to make sure a new engine platform or another Cummins product works when installed in a truck or other equipment.

The testing frequently includes a two-to-three week road trip to see what happens when the engine is stressed by extreme temperatures or elevation. Engineers say some things can only be discovered on the road.

Youre looking for gaps between systems,said Berardi, a Senior Validation Engineer in the Cummins Engine Business. Its like playing chess on a three-dimensional board.

Validation testing takes place not only at Cummins facilities in the U.S., but in China, India, the U.K. and elsewhere. U.S.-based teams have traveled as far as Fairbanks, Alaska, and Death Valley, California, to find the ideal combination of temperature and grade.
In the U.S., trips can include 8 to 10 vehicles, counting support vehicles, and as many as two-dozen engineers, some flying in to observe just part of the testing.
Winter trips mean temperatures as low as 40 degrees below zero Fahrenheit (- 40° Celsius). Summer trips can include daytime highs up to 120°F (49° Celsius). Elevation testing usually takes place at 10,000 to 12,000 feet (3,048 to 3,658 meters) above sea level.
A 17-hour day is pretty common and the most important hotel amenity is truck parking. Hotel parking lots are frequently used for emergency repairs.
Despite the challenging conditions, validation engineers say they love the trips.
I think its the chance to really see how our products work,said Jeffrey Friend, a Controls Performance Engineer based in Columbus who estimates hes been on about 30 validation trips over 17 years with Cummins. Youre out there with engineers who are experts in their field and theres no phone calls, no meetings, you just focus on the product.
The testing usually involves traversing steep grades, or going from zero to 60 miles-per-hour (97 kilometers-per-hour) as rapidly as possible commonly referred to as drag racingby validation engineers.
The fun really begins, they say, when they break something” – a catchall term that could involve just about anything limiting performance. Then the team has to figure out how to make improvements.
Thats when you get a chance to find something you can improve on before our product gets in the hands of the customer,said Beth Wendel, a Validation Group Leader in the Engine Business. That can be very exhilarating.

TALES FROM THE ROAD

After a 6-month college internship on an oil tanker crossing pirate-infested waters off the coast of West Africa, Chitresh Sharma rarely gets car sick even going up and down mountain roads looking at data on his laptop.

But the Senior Engineer in Product Validation at Cummins vividly remembers his time in a truck making run after run to test a Cummins engine in the desert outside Las Vegas, Nevada (U.S.A.). He asked the technician driving the truck they shared to turn off the air conditioning and roll up the windows to reduce drag as much as possible.

Sharma will soon be taking a new position in Cumminssupply chain organization, but he says I know Ill miss this job, and I think Ill end up missing these trips most of all.

Friend recalls how one team he was with solved the lack of suitable restaurants in Death Valley by storing deli trays in a refrigerated truck they were testing, and during a break in the desert backing it up to another truck, creating a cool area to eat.

Problem solving is really central to all aspects of these trips,he said.

Perhaps no one has more stories about validation testing than Greg Sitzman, a Mechanical Engineering Associate based at the Cummins Technical Center in Columbus. He estimates hes been on 50 validation trips over 10 years with the company.

Sitzman has been to Alaska five times, Death Valley, International Falls, Minnesota, and many other locations. Hes driven the Alcan Highway dividing Canada and Alaska, and put chains on a test truck to keep it from sliding through the Rocky Mountains. Once he even made a repair near Yellowknife in Canadas Northwest Territories parked on a frozen lake. That enabled him to easily slide under the truck.

But he says what he likes best about the trips is the camaraderie.

Comments

Popular posts from this blog

New Yuchai engine YC6K600-D30 power for diesel generator 50Hz

Technical Parameters of Boduan 500KW Weichai Generator Set 6M33D572E200

  The 6M33D633E200 diesel engine is a special-purpose diesel engine for land-based power generation in the M33 series. It is a new-structure power generation diesel engine with a centrally - located turbocharger developed by Weichai Power Co., Ltd. in 2016. Continuous Power (COP): The maximum power at which the diesel engine can run continuously under a constant load with no limit on the annual operating hours. It is the ISO standard power. Prime Power (PRP): The maximum power at which the diesel engine can run continuously under variable loads with no limit on the annual operating hours. It is an ISO standard power that allows a 10% overload. Standby Power (ESP): The maximum power in a certain variable - power series that the diesel engine can operate for up to 200 hours per year. It is an ISO standard power with limited fuel consumption.   Operating Conditions and Applications of Baudouin  500KW Weichai Generator Set  Diesel Engine Power Classification Operating Co...

Yuchai Is Super Confident in Its Innovation

Founded in 1951, with 30 wholly-owned, holding and joint-stock subsidiaries, Guangxi Yuchai Machinery Group Co., Ltd. (hereinafter referred to as the Yuchai Group) is an internal combustion engine manufacturing base with the most complete spectrum of products in the country. In recent years, machinery manufacturing industry has been dropped off influenced by domestic and foreign economic situations, especially domestic overcapacity and unreasonable product structure. Reversely, Yuchai has sold over 3 million engines with the annualized revenues amount to RMB 40 billion. Over the years, as China ’ s largest engine R&D manufacturing base, Yuchai adjusts and optimizes its industrial structure and constantly strengthens its capacity for independent innovation. Therefore, the key technology continues to be the top in the sector for further keeping its own top leader in the industry. Innovation-Driven In 2013, seven world-class diesel-engine products for high-s...