Emissions Systems

BorgWarner Emissions Systems
Emissions at a Glance
 Employees: 4.500
 Operations: 19 Locations
14 Countries
Combustion Management
•Cold start Exhaust
•Ignition System Gas Management
•EGR Module
Thermal Management •EGR Cooler
•Thermostat •EGR Valve
•Control Coolant Valve •Pipe
•Air and Liquid Heater •Air Pump
•Exhaust heat recovery
Copyright © 2015 BorgWarner Inc. 2

Thermal Management
Product Portfolio
Thermostat
wax Oil Temperature Heated Zero flow capability sleeve valve
Thermal Management
thermostats regulators thermostats thermostats thermostats
Coolant
Control Valve
Rotary Torque Motor ECCV Rotary DC Motor ECCV Linear Sleeve DC Motor ECCV
Air & Water

Heater
Air intake heater Mechanical cabin Heater LV Cabin Heater HV Heater Liquid Heater
3 QHXP DW
LF$ FW
XDW
RU
( OHFWULF
$ FWXDWRU
Exhaust Heat
Recovery PC
EHRS with Pneumatic Actuator EHRS with DC Actuator
Exhaust Heat
Recovery CD
Tail pipe Boiler EGR Cooler / Boiler

Product Portfolio
Ignition
Coils
Block & Rail Coil Pencil & Plug Top Coil Compact Plug Top Coil Multi-spark and Dual Coil
HF Ignition High Frequency

EcoFlash Ignition Systems
Glow Plug
Metallic Glow Plug Ceramic Glow Pug Ceramic Glow Plug with Close loop
Glow Plug
Control Unit
ASIC Micro-controller for glow plug (additional function available)
PSG
Pressure Sensor
Glow Plug
Metallic PSG Ceramic PSG

Metal Glow plugs for Instant Start System
Self Regulating Glow Plug

U = 11V
ISS Glow Plug U = 4V, 5V, 7V
Glow Plug Control Module
ISS Glow Plug

 Same external dimensions as self regulating glow plug available.
 Different internal structure (shorter heating coil, shorter regulating coil)
 All ceramic glow plugs are ISS glow plugs

Pressure Sensor Glow Plug – Design
Sensor electronics
Membrane with
strain gauges
Thread
Coaxial connector
M10x1 / M9x1
Glow rod
Guiding ring 4 mm Ø
15 mm
Metal bellows

Exhaust Gas Management
Product Portfolio
EGR
Exhaust Gas Management
Module
HP & LP Diesel EGR Module Gasoline EGR Module CD EGR Module
Pipe
EGR Pipe Water Cooled EGR Pipe Oil Return Pipe
Cooler &
EHRS*
HP & LP EGR Cooler Gasoline EGR Cooler CD EGR Cooler EHRS +LP Cooler
*Exhaust Heat Recovery Systems
Valve
HP EGR Valve LP EGR Vale Gas EGR Vale CD EGR Vale Actuators
Intake &
Exhaust
Intake Air Throttle valve Combination valve Exhaust Throttle Valve Actuators Air Pumps

 Gasoline EGR Systems

Gasoline EGR Market
Gasoline EGR
Improve fuel Economy
20%
CAGR
 Gasoline EGR to grow from
9% to 20% market share
Gasoline EGR
 Volume of EGR cooler >
2x by 2019 strengthening
Volume
market leadership position
EGR globally (24% market
(in Mil unit)
share)
 Volume of EGR valve >3x

by 2019
 > 2Mil gasoline EGR

modules by 2019 with
production in Europe, Asia
and North America
EGR Benefits
Cooled
External EGR
(knock resistance)
No delta-P for Cooled external EGR
HP-EGR > Enrichment reduction
Cooled LP-
EGR Flow capacity either
HP-EGR
Cooled External EGR or LP-EGR >
Load
(FE improvement by optimal

cooledcombustion
LP-EGR mixed
phasing) with HP-EGR
EGR reduces
throttling losses
(no cooling
required)
Engine Speed
Gasoline Engines – Cooled EGR
Naturally Aspirated Boosted
Catalyst Catalyst
Internal EGR
Internal EGR
EGR cooler EGR cooler

EGR valve
EGR valve
CAC
No Throttling Intake Throttle
<15% EGR 20-30% EGR

Hybrid Tube Performance Evolution
BW heat transfer technology for Gasoline Engines:
- Hybrid tubes  Wavy Fin
s1.37 fin family

s2.5 s1.6
h5.35
Diesel
Under Development
 Heat transfer enhancement based on surface h3.75
 Optimum for ε > 90 % GDi Gen1 GDi Gen3

 Good compactness
 Excellent performance in fouled conditions h2.8
 High customization due to BW fin portfolio

GDi Gen2

Awarded Bussiness for EGR in Gasoline Engines
HP EGR Module NA Engine LP EGR Module Boosted Engine
Torque motor Hot side Cold side

EGR Coolers Hot side Brush motor Brush motor

 Diesel PC HP EGR Systems

Diesel PC HP EGR Baseline Architecture
 Baseline HP EGR Architecture
WCAC AIR FILTER
TURBOCHARGER
DOC
SCR/F
ASC

HP EGR Valve Portfolio / Applications
Poppet Valve Poppet Valve Dual Poppet Poppet Valve
Torquer DC Actuator DC Actuator DC Actuator
integrated
Euro 4 Euro 5; 6
SOP 1998 SOP 2009 - 2015 SOP 2009 - 2014 Euro 6
SOP 2014
Daimler / BMW / VW… VW, PSA, Volvo, China Ford, GM VW
-Cam disc - Cam disc / Scotch Yoke -Scotch Yoke - Cam Disc

LP EGR Cooler
 General Performance Specifications

 High Corrosion Resistance Brazing for increased acid condensation
 High Cooling Power
 Reduced Pressure Drop (26 mbar @ 72 kg/h)
 Compact / Lightweight Design
 Integrated flexible EGR pipe to decouple the DPF vibration
 Installation of Emergency Filter
 Serviceable (integrated in the gasket)
 Non Serviceable (welded)
 Production Application Information

 Prototype Availability Now
 Start of Production 2007
 Production Plant Location Viana & Vigo

EGR Cooler Technologies
 Corrugated Tubes Q  U  LMTD  Ai
 Heat transfer enhancement based on turbulence
 Optimum for ε < 90 %
 Cost effective and light-weight
 Higher package volume
 Little deterioration of pressure drop at wet fouling conditions
 Large geometry diversity to meet customer’s needs

 Hybrid Tubes Q  U  LMTD  Ai
 Heat transfer enhancement based on surface
 Optimum for ε > 90 %
 Excellent performance in dry fouling conditions

 Shaped Tubes Q  U  LMTD  Ai
 Heat transfer compromise between
turbulence & surface
 Intermediate solution between
corrugated & hybrid tubes
 Trade off between Dry and Wet Fouling

HP EGR Modules – BW Manesar
 Technical points and main configurations
 HPL typical configuration
 BW offers complete EGR Module
 High performance EGR cooler. BW offers 3 types of heat transfer technologies.
 Pneumatic bypass valve. BW Manesar in mass production
 High pressure Electrical EGR valve. BW Manesar will start mass production this year

What is it Next to meet EUVI ?

EUVI EGR Diesel Arquitectures
EURO 6
CAC AIR FILTER
TURBOCHARGER
DOC
DPF
Main Trend in Low Inertia Vehicles SCR / LNT

EURO 6
CAC AIR FILTER
TURBOCHARGER
DOC
DPF
Main Trend in High Inertia Vehicles SCR / LNT

EURO 6
CAC AIR FILTER
TURBOCHARGER
DOC
DPF
HP Cooled EGR + LP Cooled EGR

Development of LV Diesel EGR Systems 2015 – 2025*
Clear Trend to Dual Loop EGR System introducing the

LOW PRESSURE EGR
* Considering applications of main diesel engine manufacturers
Copyright © 2015 BorgWarner Inc. 3 34
What is it new with the Low Pressure EGR ?

LP EGR Valve Portfolio: Throttle Valve
SOP 2008 SOP 2012 SOP 2015 SOP 2016
(product validated 2013)
BMW M57 Daimler OM651 Daimler OM654 / 656 China + Europe appl.
TÜ2 Top US 4 Cyl. Diesel 4 Cyl.; 6 Cyl. Diesel SOP 2016 + 2017
- Sensored, pneumatic - Free section 30 - Free section 28 - Flat flap 32 / / 37
- Poppet valve 27 - One-side bushing - One-side ball bearing - Both-side bearing
- Integrated axis from - Integrated axis from - Decoupled from
torque motor torque motor integrated DC-motor
Q max.: 175kg/h @ 50hPa 280kg/h @ 50hPa 250kg/h @ 50hPa 320kg/h @ 50hPa

Leakage: 25l/min @ 600hPa 70l/min @ 600hPa 70l/min @ 600hPa 26l/min @ 600hPa

LP EGR Valve Portfolio: Throttle Valve
 Valve overview Output Gear
(PA46 GF50)
Over-mold to Shaft
Non-Contacting
Cover / Sensor Crimp Ring Position Sensor
Needle Bearings
Assembly (Stainless Steel) (Melexis MLX90364)
FPM Lip Seals (2 per bearing)
(PPA GF35) High Temperature Grease
Return Spring
(1.4310)
Intermediate Gear
(PA46 GF30 PTFE15)
Valve Shaft (1.4305)

Plate (1.4301) Formed Cup Plug
(Stainless Steel)
Brushed DC Motor
Housing
(die-casted Aluminum)

Low pressure Filters
Filter to protect the compressor
From exhaust manifold To Intercooler

Turbocharger protection: Filter to
avoid ceramic particles going to the
T C compressor
TURBINE COMPRESSOR
DOC
DPF
Low pressure Low pressure

To exhaust EGR Cooler THROTTLE
EGR Valve
From admission

T C compressor
TURBINE COMPRESSOR
DOC
DPF

EGR Valve
From admission


T C compressor
TURBINE COMPRESSOR
DOC
DPF

EGR Valve
From admission


T C compressor
LOW PRESSURE
EGR FILTER
TURBINE COMPRESSOR
DOC
DPF

EGR Cooler THROTTLE
To exhaust EGR Valve
From admission

Exhaust Throttle Valves
 Baseline LP EGR Architecture
Mixer
WCAC AIR FILTER
TURBOCHARGER
DOC /
LNT
DPF
Exhaust
Throttle

Exhaust Throttle
General Product Information
Characteristics Cast Housing

• Exhaust backpressure control fit for under body operation
SOP 2018
• Thermally decoupled DC motor + 2-stage gearbox with SENT sensor, exchangeable, 140k/yr
optionally water cooled
• Non-PCB actuator cover design, welded connections
• EMC protection in actuator cover, directly above DC-motor
• Stainless steel, corrosion resistant design
Technical data
 Open position pressure drop at 450kg/h: ≤ 8 hPa
 Internal leakage range: 150…50 kg/h @ p=600 hPa
 External leakage: < 1 l/min @ p=600hPa and RT Sheet Metal Housing
 Exhaust gas temperatures: 200…500°C permanently,
max 750°C < 5 minutes, >5m/s ambient
airflow around actuator
 Ambient temperatures: -40…130°C
 Soak temp. (non-powered): -50 (<12h) …160°C (< 20 Minutes)
 Position Sensor: Non-contacting, Melexis Sensor
 Response time t90% open/close: < 80 msec
 Failsafe time t90% open: < 2000 msec
 Lifetime: > 5 Mio. full close/open cycles
 Peak Actuation Excess Torque ~ 1.59 Nm @ RT, 13.5V
 Mass: < 1.3kg (sheet metal); < 1.6kg (cast)

LP-EGR System: Intake vs Exhaust Throttling
 Technical background
 Diesel engines require a throttle to drive LP-EGR
under all operating conditions Exhaust Throttle
Hot side
 Existing throttling methods
Dual loop EGR engine layout
Intake Throttle
Cold side

LP-EGR System: Combi Valve
 Technical background
 Combine 2 functions in one product with one actuator
Dual loop EGR engine layout
EGR LP Valve
+
Intake Throttle

Low Pressure Loop
Combination Throttle EGR Valve
 Simple & Modular Dual Function Valve System

 Standard EGR Throttle Valve
 Add Inlet Diverter Wing (Intake Throttle)
 Shown Sweeping from no EGR to full EGR
 ~70% to 90 % Inlet Blockage Typical
 Weight: ~ 1Kg
Exhaust Gas
Feasibility Protoype Flow Bench Test @ 4 kPa Delta P
38 mm Air Inlet, 40 mm Throttle EGR
Mixed Gas 600 80%
To Compressor 70%
500
60%
400
EGR Rate (%)

50%
Flow (kg/hr)
300 EGR mass flow 40%
Air mass flow
Total mass flow
EGR rate 30%
200
20%
100
10%
0 0%
0% 20% 40% 60% 80% 100%
Valve Opening
Charge Air
BW Low Pressure EGR Technology
Convenctional LP Arquitecture BW Innovative LP EGR Solutions
LP EGR
Valve
+
LP Combi –Valve : Integration of LP EGR
Exhaust Throttle Valve & Intake Throttle Valve in one single
Valve valve
Especific LP EGR product available to support our customers with any

arquitecture than they want to implement

Intake vs Exhaust Throttle
 Intake Throttle is more cost effective because of the

possibility to use less expensive materials due to the
lower temperature
 There is also the possibility to integrate on the same component
different functions needed on the engine
 Exhaust Throttle has *better performance than Intake

Throttle
 *BorgWarner can minimize this difference when

designing and optimizing the complete EGR system in
terms of pressure drop

49
EGR System Pressure Drop Optimization

Integrated EGR Module – Minimum Pressure Drop

LP EGR– System Integration Solutions

LP EGR– System Integration Solutions

WHRS + LP-EGR integrated systemvation
inno
EGR
Heat exchanger
Valve
By-pass valve
PATENT PENDING Flange for connection to DPF / 3WC

inno
WHRS
EGR line
mode
Exhaust line
Coolant T
PATENT PENDING

inno
LP
WHRS
EGR
EGR line
mode
Exhaust line
Coolant T
PATENT PENDING

 CD HP EGR Systems

Low Cost Floating EGR Cooler Design
 Customer Need:
 Robust Design and Cost effective
solutions for EGR cooling to
support Emissions reduction
targets for CD (On Road & Off
Road)
 Solution:
 New design of Floating Core EGR
Cooler without expensive
and complex casting housings. The
new design provides higher
durability, more compact design,
lower weight and cost.
Keeping the Floating EGR Core , eliminating heavy

and expensive castings
58
CD EGR VALVES PORTFOLIO
Small CD Engines MD Engines HD Engines
Throttle
Throttle
FLOW REQUIREMENTS
Throttle
Dual poppet
Poppet
BRUSH ACTUATOR BRUSHLESS ACTUATOR

Torque Torque
Copyright © 2015 BorgWarner Inc.

Commercial Diesel EGR Module

Summary for New Emissions Systems
 Broad product portfolio positioned for growth
 Leading technology across all product lines
 Complete system and module capability
 Global presence to support customers needs locally
 Great customer diversity
 Local Accountability / Global Strength structure in place
 Great people and talent around the world
We are well positioned to deliver product leading

technology with exceptional value to our customers
all over the world…

Thank You
Fuel Economy Emissions Performance

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BorgWarner Emissions Systems

Copyright © 2015 BorgWarner Inc. 2

thermostats regulators thermostats thermostats thermostats

Air & Water

Copyright © 2015 BorgWarner Inc. 3

HF Ignition High Frequency

Copyright © 2015 BorgWarner Inc. 5

Self Regulating Glow Plug

ISS Glow Plug U = 4V, 5V, 7V

Glow Plug Control Module

ISS Glow Plug

Copyright © 2015 BorgWarner Inc. 6

Copyright © 2015 BorgWarner Inc. 8

Copyright © 2015 BorgWarner Inc. 10

Copyright © 2015 BorgWarner Inc. 14

 Volume of EGR valve >3x

 > 2Mil gasoline EGR

(FE improvement by optimal

EGR cooler EGR cooler

Copyright © 2015 BorgWarner Inc. 17

- Hybrid tubes  Wavy Fin

s1.37 fin family

 Heat transfer enhancement based on surface h3.75

 Optimum for ε > 90 % GDi Gen1 GDi Gen3

 High customization due to BW fin portfolio

Copyright © 2015 BorgWarner Inc. 18

HP EGR Module NA Engine LP EGR Module Boosted Engine

Torque motor Hot side Cold side

Copyright © 2015 BorgWarner Inc. 19

Copyright © 2015 BorgWarner Inc. 21

WCAC AIR FILTER

Copyright © 2015 BorgWarner Inc. 22

Daimler / BMW / VW… VW, PSA, Volvo, China Ford, GM VW

Copyright © 2015 BorgWarner Inc. 23

 General Performance Specifications

 Production Application Information

Copyright © 2015 BorgWarner Inc. 24

Copyright © 2015 BorgWarner Inc. 25

Copyright © 2015 BorgWarner Inc. 26

Copyright © 2015 BorgWarner Inc. 27

Copyright © 2015 BorgWarner Inc. 29

Copyright © 2015 BorgWarner Inc. 30

CAC AIR FILTER

Main Trend in Low Inertia Vehicles SCR / LNT

Copyright © 2015 BorgWarner Inc. 31

CAC AIR FILTER

Main Trend in High Inertia Vehicles SCR / LNT

Copyright © 2015 BorgWarner Inc. 32

CAC AIR FILTER

HP Cooled EGR + LP Cooled EGR

Copyright © 2015 BorgWarner Inc. 33

Clear Trend to Dual Loop EGR System introducing the

Copyright © 2015 BorgWarner Inc. 35

Q max.: 175kg/h @ 50hPa 280kg/h @ 50hPa 250kg/h @ 50hPa 320kg/h @ 50hPa

Copyright © 2015 BorgWarner Inc. 36

Valve Shaft (1.4305)

Copyright © 2015 BorgWarner Inc. 37

From exhaust manifold To Intercooler

Low pressure Low pressure

Copyright © 2015 BorgWarner Inc. 38 38

Low pressure Low pressure

Copyright © 2015 BorgWarner Inc. 39 39

From exhaust manifold To Intercooler

Low pressure Low pressure