Cummins deploys new wedge capsule engine braking technology across three engine platforms
Cummins Inc. [NYSE: CMI] has confirmed that its new wedge capsule engine braking technology, designed to deliver faster engine braking and more fuel-efficient brake-assisted gear shifting, will be deployed across three Cummins HELM engine platforms: the 2027 X15, X10, and B6.7 Octane engines.
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The patented wedge capsule hardware, available on the crosshead, rocker arm, and pushrod valvetrain components, drove the company’s decision to develop its first-ever mechanical engine braking system. It offers an alternative to the high-pressure hydraulic chamber used in conventional compression-release engine braking systems.
Removing the hydraulic chamber improves brake response time by up to 60% without losing capability. It reduces the average duration for slab brakes from 300-350 milliseconds and for rocker brakes from around 250 milliseconds to less than 100 milliseconds in the Cummins X15 engine.
For OEMs using automated manual transmissions (AMTs) with engine brake-assisted gear shifting, wedge capsule technology extends the performance envelope. The wedge capsule’s 100-millisecond response shortens the brake activation window, reducing vehicle speed droop and the fuel penalty of re-acceleration after gear engagement.
The wedge technology uses a two-step actuation mechanism that protects the system during partial engagement, a known failure mode in other mechanical engine brake designs that use single-actuation pin-lock systems. When partial engagement occurs, the wedge geometry limits load transfer to approximately 30% of full actuation force, preventing component damage. The system also requires no crank angle-based activation control, simplifying integration for OEM engine management calibration teams.
Another benefit is eliminating hydraulic compliance: in hydraulic systems, oil compressibility under high valve loads causes lift loss, which must be compensated for with additional cam lift. A mechanical load path removes this variable entirely.
Wedge capsule technology deployed on three Cummins platforms
Wedge capsule technology is offered on the 2027 HELM X15, X10, and B6.7 Octane engines.
On the X15 engine, wedge capsule technology is deployed in the compression-release engine braking system, where it delivers the highest total braking power in its class. On the X10 engine, the technology is integrated into the Jacobs® High Power Density® (HPD®) engine braking system, using two capsules: one for cylinder deactivation (CDA) and the other for braking activation. The X10 engine will deliver the highest specific braking power in its class.
On Cummins’ first gasoline-powered engine, the B6.7 Octane, the wedge capsule is integrated into the rocker arm, adapted from the collapsing pushrod architecture developed during Jacobs® cylinder deactivation program. The mechanical brake system on this platform is designed to work with hydraulic lash adjusters (HLAs) and Cummins cam-phasing technologies.
Gabe Roberts, Director of Product Development – Cummins Valvetrain Technologies, said, “The capabilities unlocked by wedge capsule technology, and particularly the two-step activation mechanism, are key to Cummins launching its first-ever mechanical braking system for these Cummins engines. OEMs have a strong need for fast brake activation, and solutions that enable faster engine brake-assisted gear shifting are also highly sought after.
“Following over 15 years’ development of collapsing technology that started with the Jake Brake® and progressed into High Power Density engine brake and Cylinder Deactivation products, wedge capsule technology is the latest evolution in valvetrain technology from Cummins. Cummins has a collapsing technology for every type of valvetrain in commercial vehicles, and each of these new Cummins engines is future-proofed for the integration of advanced technologies, including HPD and CDA,” concluded Roberts.
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