Tier 4, It's Here – So Are the Design Challenges

Many engineers, designers and managers were introduced to the concept of Tier 4 emission regulations for off-road equipment a number of year ago. Some were exposed to it in 2007 and earlier. Exposed to it as a way of saying “heads up, here is what is to come” while brutally facing design challenges and nightmares attempting to release Tier 3 equipped machines and equipment.

When construction and off-road equipment manufacturers started preparing for Tier 3, many challenges were faced. New engines requiring new mounting spaces, different sub structures and greater cooling capacities were a small percentage of such challenges.

With Tier 4 arriving, these same engineers whom had already been exposed to the Tier 3 design are facing a completely new set of challenges. A set of challenges that would far exceed anything they had faced in the past. Not only would Tier 4 mark the presence of more stricter emission standards, it would mark the presence of possible complete machine and equipment redesign.

When Tier 3 rolled around, changes such as increased engine space claims, larger cooling capacities and greater air flow requirements meant an increase in engine compartment size, redesigned engine hoods and covers and a means of stuffing more air into the engine. In some instances, Tier 3 pushed the limits of machine design while still keeping the current overall width, length and necessary ground clearance. These new Tier 3 equipped machines were bulging at the seams from the addition of these increased coolers and engine compartments, leaving no room for such items as DPF systems soon to come with Tier 4.

These Tier 3 machines had been packed, filled and crammed as much as possible to incorporate the necessary design changes required for the Tier 3 engines. This left engineers with just one question for Tier 4. “Where do we place items now that we have run out of room”? This very question left many engineers scratching their heads, as there was no room to stuff a single extra component now that Tier 3 had been deployed. For many, this left only one option; complete machine redesign. An option that was not easily taken, especially since the deployment of Tier 3 had taken every last available resource, placing new product development on hold.

Tier 4 is more than just emissions standards. For some, it is possible complete machine redesign resulting in lengthened frames, new placements for existing counterweights, new driveline components and much more. The budget for Tier 4 integration is popping at the seams leaving Directors searching for every last opportunity to cut cost and shave a few dollars.

Equipment purchasers and rental agencies were reluctant at new equipment purchases approaching Tier 3 release. Equipment prices were elevated due to the rising engine and component cost while some rental agencies and excavating companies were seeing a drop in projects and customer demand. Stepping into Tier 4 development, many engineers and department heads know significant cost reductions have to be made in order to offset increased product and manufacturing costs. Costs that the end user can not and are not willing to afford. Cost reductions of this magnitude have already been implemented by automotive companies removing under hood sound deadening blankets, glove box lights and other various minor items and accessories that were mere standard equipment a few years back.

With the ever growing increased use of new technology and implementation of new stricter standards, price tags continue to climb; both for the component manufacturers and OEM manufacturers. With end users already financially strapped for cash and operating budgets about to burst, the increased cost of Tier 4 is not setting well with many, who are running cost analysis comparisons on replacing a few aging pieces of equipment vs. running, repairing and maintaining items in their old fleet for a few more years.

As President and CEO of Engineered Systems Controls Corporation, John brings a rich background in product development, filtration solutions and off-road equipment design. Prior professional experiences include product development for a multi-billion dollar off-road equipment manufacturer and engineering coordinator for physical security product solutions for commercial and military applications.

Engineered Systems Controls Corporation is a global enterprise developing and manufacturing filtering solutions for a wide range of markets including industrial and off-road applications, performance motor sports, agriculture and class 8 transportation. The products offered can be found in a wide range of industries around the world including Commercial, Agriculture, Construction, Forestry and Mining.

Engineered Systems Controls Corporation
http://www.engineeredcontrols.net