Torque Curves

PRODUCT INFORMATION
P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
How a Torque Curve is Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What the Torque Curve Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Changing the Torque Curve Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Transient Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Information and Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3
 P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

TORQUE CURVES
Torque curves are used by performance • How Torque Curves are Created
engineers to graphically express a diesel
engine’s ability to maintain torque output at a • What the Torque Curve Means
reduced speed. In simple terms, a torque curve
(also called “lug curve”) is a performance map
• Changing the Torque Curve Shape
created for a given diesel engine. • Operating Factors
This manual will present the following • Transient Performance
information to help the user/operator understand
how torque curves are created, and their • Summary
relationship to engine application.

4
P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

HOW A TORQUE CURVE IS CREATED

Diesel engines have two performance limit Rack Settings
controls — high idle and rack settings. These
For each constant rack position (such as might
settings are made on the engine governor. The
be used by the rack stop) a certain torque speed
high idle setting establishes the top operating
is obtained. The shape of this curve is
speed of the engine, while the rack setting limits
determined by several engine characteristics
the amount of fuel that can be injected per stroke.
including: injection pump efficiency, combustion
To build the performance map — or torque curve
efficiency, breathing (or volumetric) efficiency,
— these two limits must be considered separately.
friction. The shape of the curve is characteristic
High Idle Setting of the given engine and can be changed.

High idle is the maximum speed the engine will For every rack setting there is a torque speed
run with the governor wide open. In other curve. As with high idle settings, this means that
words, through the governor, this setting each engine actually has a whole family of
establishes a speed at which the engine operates torque speed curves. This group of curves is
when the speed control is wide open. As load, or subject to various engine efficiencies and
torque requirement, is added to the engine, the operating conditions just like a single curve.
governor opens the rack to maintain the engine The operating map is created by superimposing
speed which is set by the high idle stop and the the two families of lines. The result is a grid of
governor position. Under isochronous governor the entire operating torque speed range of the
control, the torque speed relationship looks like engines.
a straight vertical line.
There are limits which dictate where an engine
When mechanical governors are used, the engine can operate successfully. These include: speed,
slows down slightly as load is added. This speed smoke, temperature, etc.
change activates the governor. It is a relatively
TORQUE CURVE MAP
small change and can be varied by governor
design to suit the need.

TORQUE

HIGH IDLE
TORQUE SETTING

ENGINE RPM

Turbocharged Engines
ENGINE RPM
If the engine is turbocharged, limit lines (a
The various high idle settings result in a whole fence) may be drawn around that part of the
group or “family” of torque speed lines with torque speed graph which is usable by engineers.
slants determined by governor characteristics. If This is the part of the performance data which
the high idle stop is set at a given position, and can be appropriately used for selling. There are
load is added to the engine, the engine speed engine high and low speed limits, turbo speed,
drops slightly according to the characteristic exhaust temperature and smoke which are all
slant (or droop) of the line for that setting. factors.

5
 P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

WHAT THE TORQUE CURVE MEANS AND

HOW IT IS USED
Any chosen high idle setting and rack setting Several factors come into play to add additional
will result in a single torque curve. The curve torque as the engine lugs down. Any
will be made up of two parts — the overrun combination of these can contribute to torque
portion, where the engine speed and rack rise:
positions are controlled by the governor, and the
lug part of the curve, where the rack is against • Fuel Injection Equipment – may be more
the stop and additional load causes the engine to efficient at lower speeds and the engine may
slow down. get more fuel per injection pump stroke even
though the rack stays constant.
LUG CURVE LIMITS

• Combustion Efficiency – may increase at

lower speeds as the injected fuel may burn
more thoroughly.
TORQUE
• Air Supply per Piston Stroke – may be
greater at lower speeds, due to an increase in
volumetric efficiency. This air increase can
assist in burning fuel more efficiently and
ENGINE RPM
result in an increase in torque.
The point at which the overrun and the lug meet
on the torque curve is called the balance point. • Friction Decrease – also contributes to
This point is used as the engine’s rating, as this torque rise
is the point of maximum horsepower (where the
engine is doing the most work.) The difference in speed (rpm) between the
balance point and high idle is the overrun, or
High idle, the maximum speed the engine will speed regulation. With vehicular governors this
run with the governor wide open, is limited by may be 7-10 percent of rated speed, and may be
the high idle setting. At the balance point, the as low as 3 percent for generator sets where
rack hits the rack stop and cannot be opened close regulation is required.
further. When more load is added, more fuel
cannot be injected unless a torque spring is used. Overrun is zero on isochronous governors.

In the lug portion of the curve, two factors are

PEAK TORQUE important:
POINT

TORQUE
• Torque rise
RISE • The speed at which the peak torque
BALANCE
TORQUE POINT occurs
OVERRUN
Torque rise is generally expressed in percent
LOW HIGH increase over rated torque at the balance point.
IDLE IDLE
This torque rise is related to the diesel’s ability
ENGINE RPM to “hang on” under overload and is, therefore,
an important feature.

6
P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

CHANGING THE TORQUE CURVE SHAPE

The ideal development target is to have the Factors which will affect torque rise and
torque peak between 60 percent and 70 percent subsequent engine performance include:
of rated speed. A typical diesel engine of today • Load
might have 1000 lb-ft of torque at 1800 rpm and • Combustion efficiency
lug to 1200 rpm. This is a 20 percent torque rise • Governor action
at 67 percent of rated speed. High idle for this • Turbocharger
engine might then be 2150 rpm, or 17 percent
overrun. Load
Another way to change the torque curve shape is Load has a very definite effect on the action and
by using a mechanical device such as a flexible feel of the engine. Acceleration, for example,
rack stop or torque spring. The engine can be will vary considerably depending upon how
given more fuel during lug operation by much load it is carrying. An engine with no load
allowing the rack to open an additional will accelerate to full speed within seconds, as it
controlled amount. Such devices simply allow must speed up only its own mass.
the torque curve to be modified by a more open
rack position as the engine lugs down. This Acceleration is inversely proportional to mass. If
results in a high torque curve. a heavier flywheel or load is added to the
engine, it will accelerate more slowly. There is
To avoid mechanical failures or complaints
enough power in the typical shovel engine to
about excess smoke, upper operating limits (ie:
spin the shovel like a top once it is up to speed.
turbo speed, smoke, and exhaust temperatures)
But because the shovel swing is less than 180°,
are not exceeded.
the engine barely gets the swing started when
A torque curve with no torque rise is unable to the shovel must be braked and the engine must
carry additional torque beyond what is rated. start the reverse swing. The same problem holds
true when the engine has to start up a rock
Operating Factors Affecting Torque
crusher or other large, high mass equipment.
Rise/Engine Performance
Torque rise cannot be measured with instruments In vehicles, a transmission is used to get high
as in a laboratory. Rather, the operator has to torque multiplication for acceleration. This
feel the change. This means he or she must feel approach is also useful in other applications.
acceleration or changes in speed; the load being A torque converter provides torque
moved or the engine stalling. multiplication at low output shaft speeds. The
Because many of the overload torques are shaft output torque of the torque converter takes
required only for a short period of time, the the place of the flywheel output of the engine,
operator may feel the amount of speed drop so far as the load speed characteristics are
when the engine hits the overload. In some concerned. Engine speed varies through a
cases, even the sound of the engine may indicate small range and the engine does not stall
either extra power or sluggishness. with a converter.

7
 P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

CHANGING THE TORQUE CURVE SHAPE

The torque multiplication advantage of the • Turbocharger
converter is exchanged for some power loss due The turbocharger is also responsible for
to converter inefficiency. some lag time in engine response. However,
two factors must be considered. First there is
• Combustion Efficiency
generally excess air in the cylinder, more
The speed with which an engine responds to
combustion begins at once — even before
load demands is directly proportional to the
the turbo speeds up. Full power will be
size of fire that can be built in the
reached only after the turbocharger speed has
combustion chamber and how quickly it can
moved substantially toward its rated speed.
be built. Cold engines just started would not
respond as rapidly as hot engines because Second, the turbocharged engine generally
the cold combustion chamber walls tend to has less inertia or mass within its own
inhibit good combustion — and because the rotating parts than does a similarly rated,
oil drag would be too high. naturally aspirated engine.
• Governor Action If these factors are considered, turbocharger
When the engine is given more load, it slows lag is not a problem on an engine which has
down momentarily. That slowing action been properly matched by the turbo.
causes the governor to open the rack to get
more fuel for the engine. The time this takes
is lost time and can be a significant part of
response time.

8
P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

TRANSIENT PERFORMANCE
Transient performance is of interest in engine This brings us to the fact that the torque curve is
application because, in rapidly changing a two-way street. In some applications, the
conditions, the engine does not exactly follow engine must pick up both load and speed. The
the steady-state torque curve. engine may start at the low idle point and work
up the back side of the torque curve.
In theory, if the engine governor is wide open
and the engine is running at high idle as load is Transient data taken in this manner shows that
added, it will slow down slightly with increased there is also a possibility of variation from the
torque until it reaches the balance point. Then torque speed curve if that load change or load
the engine will follow the lug part of the curve, application is rapid enough.
slowing down more as additional load is added
This is characterized in such uses as drill rigs.
until the torque peak is reached. Here, of course,
The direct drive drawworks engine must pick up
any further load will stall the engine.
the load, a string of pipe, at a very low speed in
If the load is applied rapidly, something different order to avoid shock damage to the drawworks.
can occur. The engine output torque may It must then accelerate that pipe to perform the
actually be less than the torque curve indicates. operation in a reasonable time.
At the same time, the high rotating energy of the
Low speed torque is very important in such an
engine flywheel drive system is transferred to
application. High horsepower alone — at rated
the load in such as way that the load feels an
engine speed — may mean nothing. The
entirely different torque (at least momentarily).
drawworks engine is “loafing” when it reaches
This illustrates the advantage of the engine and rated speed.
drive inertia in picking up loads when the engine
Here it becomes important to know which way
is operating at high idle. In this instance,
the engine will pass through the torque curve.
flywheel mass is good, but the operator must
also remember that, when the engine lugs down,
• Will it lug down from high idle and then
it must also speed back up before it can pick up
recover with no load?
another load cycle. The engine must also carry
that same flywheel mass back up with it. If • Will it start from low idle and pick up both
response is critical, the excessive flywheel mass load and speed?
may be a source of trouble. • Will it operate in some intermediate manner?

9
 P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

ADDITIONAL INFORMATION AND

CHARACTERISTICS
In general, when an engine lugs down from high LOAD MAP
idle, it is good to stay above the peak torque G F E
point. This is not, however, absolutely necessary.
D
Some operators lug their engines down until it
is almost possible to count the firing strokes C
TORQUE
without stalling the engine. In other applications,
B
the same model engine stalled as if it had no
A
power at all. The load demand of the application
is probably the reason. By controlling the load,
the operator was able to actually work on the ENGINE RPM
back side of the lug curve where steady
operation would not be stable. If the load is adjusted to condition E, the engine
will lug down still further. Now, by adjusting the
The torque speed characteristic of the load load, the engine can be made to operate between
demand can be plotted in the same manner used these two points on the lug curve. This condition
to plot the torque speed curve of the engine. One is stable as long as the load curve intersects the
application may require nearly constant torque engine curve and the load torque requirement is
for steady operation. Other applications may less at the next lower speed than what the engine
require increased torque as speed goes up. Still will put out. This holds true all the way to load
other applications may require a combination of F and shows how an engine can operate on the
characteristics. back side of the lug curve if the load is under the
TORQUE REQUIREMENT TYPES operator’s control.
By describing unstable operation we have
inferred that where the two torque curves
crossed, the operation would be stable. This
TORQUE
REQUIREMENT condition is also one that can also be felt by the
operator. Further, the greater the angle of the
intersection between the load demand curve and
the engine torque curve, the more stable the
operation will be. By controlling the load, the
SPEED – RPM
operator can move the torque requirement and
If, for example, an engine is attached to a manually operate the engine in the speed range
variable load, the possible torque speed demands in which he desires to work.
for the different load conditions would form a
LOAD CONDITIONS
family of torque curves. Over this, one can
superimpose the engine torque curve. Now the
engine will operate at the condition determined UNSTABLE
STABLE
by the intersection of the engine torque curve
and the load curve. TORQUE

If loads A, B, or C are used, the engine will VERY STABLE

operate on the overrun portion of the curve. If

the load is adjusted to condition D, the engine
will lug down to a lower speed. ENGINE RPM
10
P R O D U C T I N F O R M AT I O N – T O R Q U E C U RV E S

SUMMARY
Torque curves are useful tools by which the The torque characteristics can be used in the
engine can evaluate diesel engine performance. application of engines if the applications are
They are influenced by design variables known. Poor torque characteristics may be the
which can be manipulated to obtain specific cause of poor diesel engine performance and
characteristics in the engine. They can be unsatisfactory results in their application.
changed by governor setting and by special
torque spring devices in order to obtain special
characteristics.

11
LEKX6306 Printed in the U.S.A.
© 1996 Caterpillar Inc. All rights reserved.