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Dream

Latest engine technology minimisesnoise, vibration and emissions andimproves efficiency.

By Guy Waddilove

Marine engine manufacturers are accountingfor modern thinking when it comes to newproduct development. Once the design anddevelopment of marine engines was driven bycustomers’ desire for speed and acceleration;now other criteria are given priority.Cleaner exhaust emissions have beendeveloped to satisfy environmentalregulations. The International MaritimeOrganisation, the European Union (EU) andUS are introducing strict requirements foremissions from diesel engines in leisure craft.Engine manufacturers have been obliged todevelop engines to produce less noxious gasesto comply with the various regulations.Additionally, the closely related criteria of fuelefficiency and economy are now priorityfactors in the minds of customers.Customers are also demanding quieter engineswith less vibration than before. One of themajor developments in diesel engines thataddresses these points is the common rail direct

fuel injection. With this system, fuel is fed by asingle rail at high pressure to individualelectronically controlled solenoid orpiezoelectronic injection valves. Older types ofdiesel engines relied on mechanically-controlled, low pressure pumps supplying fuelto spray nozzles. Common rail systems permitvery accurate control over the timing andamount of fuel supplied to the cylinder. Thesolenoids can be set to inject a small amount offuel prior to the main injection to reduceexplosiveness, vibration and noise. As the fuel isat much higher pressure, better atomisationoccurs giving a more efficient and cleaner burn.Another factor driving engine developmentis physical size. With engines becomingmore efficient, smaller sizes can now bespecified, freeing space for otherequipment. Overall weight is alsodecreased, further improving economy.As engines become more sophisticated so toohave control and monitoring systems. Withengines controlled electronically, associatedmonitoring systems can be integrated to giveaccurate digital displays of performance andsafety overrides and alarms. Electronic throttleand gear operation is more precise thantraditional push-pull Morse cables.

With electronic “brains” at the centre ofengine systems, manufacturers can combinesteering, trim and thruster commands intopropulsion plants to fully integrate systems.For example, Volvo Penta has integratedthrottle and leg steering systems to allow twoengines and steering functions to becontrolled with one lever. MTU hasdeveloped a system integrating throttlecontrol with trim for its surface-piercingpropeller legs optimising performancethroughout the speed range.Bow and stern thruster development iskeeping up with technology with compositeunits in place of metal housings. The benefitsof research on propeller blade shaping andpositioning is also reflected in recent products.

ENGINESMTUMTU Friedrichshafen has introduced Maritune,a system for surface drive propellers thatautomatically adjust for optimum depth. Enginespeed and trim settings are pre-selected for eachcontrol lever position. Software continuouslyadjusts trim settings whilst the vessel isunderway. The electronically controlled systemallows speed and trim to be controlled with a

ocean | 147

single lever optimising acceleration,manoeuvring, banking and astern operation.Thus, negotiating heavy seas is easier for theskipper. An integrated steering function furtherenhances the auto-trim facility, therebyeliminating hydraulic lines. Trimming andsteering is via a single hydraulic unit with anindependent pump for each function. Allsystems are displayed on a single monitor screen.MTU demonstrated Maritune’s capabilitiesduring practical trials on a Mangusta 80powered by two MTU 16V 2000 commonrail engines; the automatic trimming systemreduced acceleration times up to 30 percent.As a systems provider, MTU suppliescomplete propulsion plants with all hardwarefrom propulsion control lever to propeller,including software. The Maritune system iscompatible with all plants equipped withMTU Series 2000 or Series 4000 engines.

Volvo PentaVolvo Penta’s new propulsion system, theInboard Performance System (IPS), featurespropellers that pull rather than push. Thepropellers are on forward facing drives

through the bottom of the hull and counterrotate giving greater efficiency over shaftdriven hulls. According to Volvo Penta'scalculations, the IPS will produce 20 per centmore speed, give 15 per cent betteracceleration and cut noise and vibration by 50per cent. These improvements are achievedwith propellers rotating in undisturbed water.Backwash runs parallel with the boat's bottomso all power developed drives the boat.Rotational inefficiencies are eliminated viatwin counter rotating propellers.Manoeuvring is simplified by turning thedrives like rudders. Because the units turn, theentire thrust is correctly aimed.Volvo Penta has four versions: IPS350,IPS400, IPS500 and IPS600. The range isappropriate for boats from 35-50 feet.At the top of the range the new Volvo PentaIPS600 represents state-of-the-art dieseltechnology with electronically-controlledcommon-rail fuel injection, double overheadcamshafts, four valves per cylinder,turbocharger, intercooler and compressor. Thecompressor operates immediately duringacceleration at low revs, creating powerfultorque. At higher revs, the compressordisengages and the turbo takes over, resultingin improved acceleration and higher torquethroughout the entire range.All of the engines feature common-rail fuelinjection. To further reduce vibration, theengine blocks are reinforced with a special“ladder frame” and cylinder head cast as asingle unit.The engines’ exhaust emissions are extremelylow and will likely meet the requirementsplanned for the EU and US in 2006-2007.The entire system - from steering wheel topropulsion units - is electronically controlledand integrated via Volvo Penta's EVC(Electronic Vessel Control) system. Each unit islinked to a steering gear powered by an electricmotor. The system processes the skipper’s wheelinput and converts it into movements of thepropulsion units. EVC is a sophisticated systemthat takes into account water flow along thebottom of the boat at different speeds. Thesteering is progressive, making it easier to turnthe wheel at low speeds.

Cummins MerCruiserCummins MerCruiser Diesel (CMD) will adda new series of engines to its range at theSanctuary Cove International Boat Show inMay. The new QSD series, designed for stern

drive and inboard applications, is based on thesuccessful, high pressure common rail fuelsystem design introduced on its largerrecreational and commercial engines. Each aredesigned as drop-in replacements for petrol-engined applications; the 4.2 litre engine, forexample, has been shortened by over 100mmto simplify retrofitting.The engines’ common rail fuel system isdesigned to reduce smoke, noise and vibrationand to provide rapid power delivery.Turbocharger and seawater aftercooler areredesigned for improved throttle response andperformance while newly-designed torsionalcouplers are used for a smoother ride in inboardapplications. Modernised components likeintegrated heat exchangers and exhaustmanifolds enhance the QSD design strategy ofreducing engine weight and size.

The QSD range features an advanced ECM(Electronic Control Module) with SmartCraftcompatibility. This system constantlymonitors engine performance parametersproviding instant diagnostics and operationsdata at the helm via a digital display.The QSD series is a development of CMD'sfour- and six-cylinder diesels and includes 2.0,2.8 and 4.2 litre engines with ratings spanning85 to 257 kW (115 to 350 hp). The enginesmeet US EPA Tier 2 emissions regulations.Cummins MerCruiser Diesel is a 50/50joint venture between Cummins andMercury Marine.

CaterpillarCaterpillar developed strategies to makeengines cleaner and more environmentallyfriendly. ACERT (Advanced CombustionEmissions Reduction Technology) representsCaterpillar's US$500m investment in thetechnology and is based on models which map

146 | ocean

ENGINE ROOM

New Sea Friendly Diesels

The new 75ft Lazzara LSX express yacht is the world’sfirst boat to install four Volvo Penta IPS drive units

the combustion process in the cylinder duringall phases of operation including full and partload, acceleration, deceleration and idle.Working with these models, engineering staffvaried airflow, fuel injection timing andmultiple fuel injections per revolution withthe results used by Caterpillar engineers toimprove the combustion process.

One of the results was the refinement of theADEM electronic engine managementsystem. The ADEM module was upgraded tocontrol multiple injections of fuel into eachcylinder, revised fuel mapping and valvetiming, combustion control and improvedengine monitoring.It became evident that the efficiencies gaineddelivered other benefits including lighterengines and power increases of 10 per cent.

THRUSTERSMaxpowerMaxpower has incorporated compositetechnology adopted from the automotiveindustry in its latest line of electric thrusters.Composite moulded legs are now used in

place of aluminium or steel housings to give amaintenance free drive leg. Assembling theunit from composite avoids electrolysis andcorrosion without anodes.The composite thruster has electronic controlin line with all recent Maxpower electricthrusters. The more usual thermal overloadtrip is replaced by an audible alarm allowingthe skipper to continue running the thruster.This overrides the overheat alarm allowingescape from dangerous situations.

Side-powerSide-power has introduced a radio-controlledremote control for use with its bow and sternthrusters. The waterproof unit is boat-shapedto avoid confusion with port and starboard

and possible misuse when the operator isabsent. Accidental activation is avoided withan on/off button and a cut out switch.

VETUSVETUS’s new six-bladed thruster will beinroduced at the Sanctuary CoveInternational Boat Show. Developed incollaboration with the Maritime ResearchInstitute Netherlands, the six blades arespecifically shaped to reduce cavitation andnoise whilst increasing power by 9 per cent. Asthere is only one propeller, the thruster workswith small tunnel length applications, and theblades' shaping allows it to produce equalpower to port or starboard.

Control SystemsVolvo PentaVolvo Penta has introduced joystick controlto further aid manoeuvrability for boatswith its IPS engines. The joystick can beretrofitted and allows single-handedmanoeuvring in all directions at enginespeeds up to 1,500rpm. Software translatesthe joystick’s movement into specificthrottle, gear and steering instructions.Using the joystick with the steerable driveunits allow the boat to move directlysideways, rotate within its own length ormove forward or astern at an angle. Thejoystick function is cancelled by pressingthe connection button or by turning the

steering wheel or touching the throttle orgear levers.

Micro DeviceMicro Device of Italy has produced the YachtController, a wireless remote control aboutthe size of a mobile phone. The YachtController integrates controls for two engines,bow and stern thrusters and anchor windlassto enable full control when manoeuvring anddocking from any part of the boat. Thecontroller runs on two AAA batteries and,should a malfunction occur, the unit reverts tosafe mode making the helm station controlsactive. Each unit is coded to avoidinterference from similar equipment.One advantage with the yacht controller is theunit will operate from anywhere on the boat,saving installation of extra steering/controlstations only used for docking andmanoeuvring. It may also save on repairs toscratches and bumps!

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ENGINE ROOM

CONTACTS:

MTU Detroit Diesel Australia Tel: +61 3 9243 9234 www.mtudda.com.au

Volvo Penta OceaniaTel: (07) 3902 5444www.volvopenta.com.au

Cummins MerCruiser DieselTel: 07 5500 9060www.cumminsengine.com.au

Australian Caterpillar Engine Dealer:Energy Power Systems AustraliaTel: 1800 800 441epsa@energypower.com.au

Side-Power Thrusterswww.side-power.com

Maxpower thrustersTel: 02 9981 9500www.oceantalk.com.au

VETUS AustraliaTel: 07 3356 9808www.vetus.com/

Yacht Controller,Tel: 0411724176www.yachtcontroller.com.au

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