Shaw Development: Improving Engine Operability with Custom Fluid Management

The Environmental Protection Agency (EPA) has implemented ultra-low NOx (Nitrogen Oxides) regulations for on highway and off-road machinery. These regulations have forced engine manufacturers to use SCR (selective catalytic reduction) by means of diesel exhaust fluid (DEF) to break down NOx levels into harmless nitrogen and water molecules while allowing the engine to be more efficient and reduce fuel consumption.

However, there still remains significant room for improvement in DEF reservoir systems. Most of the DEF fluid level and quality sensing solutions used for emission control system are based on reed switch, infrared or tuning fork resonance technology. These products are not rugged enough to operate in extreme weather conditions, especially in freezing or high temperature environments. When DEF freezes or hydrolyzes (high temperatures), the sensors are unable to operate. In the short-term, it may cause the sensors to believe a vehicle’s DEF tank is empty or has improper quality of DEF fluid and prompt a de-rating event, which reduces engine power and eventually prevents the engine from restarting.

Shaw Development is eliminating this longstanding market impediment with its advanced DEF systems using ultrasonic level and quality sensors that are operable under extreme environmental conditions. Powered by ultrasonic sensing technology, Shaw Development tackles the sensors durability issues when DEF freezes or reaches temperatures over 70C (158F), thereby increasing the robustness, uptime and performance of the vehicle.

“Our customers across various sectors expect us to provide the cutting-edge fluid management solutions for both on and off-road heavy duty vehicle applications using our turnkey ultrasonic sensor-based DEF systems,” says Kurt Schuering, VP of Global Sales, Marketing and Technology, at Shaw Development.

Apart from solving the sensor inoperability issues, Shaw Development’s DEF system has also found a fail proof way to thaw DEF in any condition. The DEF reservoir’s multifunction head unit includes a heating element that is capable of thawing Diesel Emission Fluid when DEF freezes and can operate when external temperatures drop as low as to -40C (-40F).

An additional benefit is Shaw Development’s ability to tailor the sensor electrical outputs to meet the client’s specific needs. Shaw Development’s team of electrical engineers have a thorough understanding of the engine control modules inputs to allow for accurate programing of the sensors. Since the company controls both engineering and programming needs in-house, there are fewer intermediaries in the process.

“Our leading-edge solutions are further bolstered by a deep-seated mindset of continuous improvement, multi-generation product plan strategy, and a white-glove approach to client engagement,” says Nick Delihas, Director of Product Line at Shaw Development.

A case in point is with a major Japanese OEM manufacturer of wheel loaders. The heavy-duty vehicle application was facing slosh-induced driving problems. Shaw Development stepped in to support and carried out an extensive development project, replicating a similar environment, to test sensors in these severe conditions. Shaw’s engineering team implemented the required design changes in their final product. The necessary geometrical modifications to the product successfully eliminated the adverse effects of slosh on the wheel loaders’ DEF systems, significantly improving efficiency of the vehicles.

Shaw Development remains proactive both in terms of production capability and design flexibility with investments in technology. Primed with this steely determination around customer experience and a zeal for innovation, Shaw Development is set to expand and diversify its product portfolio, allowing customers from all sectors to benefit from their best-in-class DEF systems.