Four new designs cover a wide range of engine sizes
Enhance coolant distribution and provide high robustness against thermal fatigue
Help commercial vehicles with natural gas engines meet emissions regulations
Auburn Hills, Michigan, August 1, 2017 – To support commercial vehicle manufacturers in meeting current and future emissions regulations, BorgWarner has developed an economical new series of multi-platform exhaust gas recirculation (EGR) coolers featuring a compact floating core. Unlike conventional solutions which must be specifically designed for each application, the company’s modular cooler family includes four highly adaptable standard designs for maximum flexibility covering a wide range of engine sizes from 2.0- to 16.0-liter displacement. The new EGR solution offers high robustness against thermal fatigue and enhanced coolant distribution for durable performance even with minimum coolant flow, while reducing NOX emissions.
“With lower production volumes and high durability requirements, the commercial vehicle segment needs an EGR solution that provides outstanding performance and reduces complexity at the same time,” said Joe Fadool, President and General Manager, BorgWarner Emissions & Thermal Systems. “Offering high flexibility and durability, our newly developed EGR coolers have already piqued the interest of several manufacturers that see the potential for a cost-effective solution to help meet increasingly stringent emissions regulations.”
Featuring hybrid tube heat transfer technology and a floating inner core, BorgWarner’s EGR coolers are designed to resist high levels of thermal load. In addition, the system provides enhanced coolant distribution, which enables durable performance even with minimum coolant flow. BorgWarner integrated a thermomechanical damper into the design to facilitate complete decoupling of the shell and inner core components to absorb longitudinal and angular differences for improved durability. The damper also provides some initial extra cooling for the inlet gas to reduce thermal shock and allows better gas distribution to the tubes to resist thermal fatigue. In addition, cooling the damper and inlet gas box reduces the overall temperatures achieved, which in turn significantly lowers thermal stress. When the system is operated at an exhaust gas temperature of 1,562°F (850°C), the inlet gas box temperature is kept below 392°F (200°C), compared to more than 1,292°F (700°C) without cooling. The advanced design also minimizes the effect of the engine transients over the EGR cooler’s durability. The four new coolers allow the standardization of most of the components from one application to another, with the exception of the housing and the mounting fixtures, resulting in maximum adaptability for robust, tailor-made solutions and high cost-efficiency.
BorgWarner’s most compact turbocharger for 1.0-liter engines
Boosts performance, improves fuel efficiency and reduces emissions
Delivers quick response with low noise, vibration and harshness as well as an excellent power density
Auburn Hills, Michigan, July 11, 2017– BorgWarner, a global leader in clean and efficient technology solutions for combustion, hybrid and electric vehicles, delivers its proven wastegate turbocharger for Honda’s new three-cylinder 1.0-liter gasoline direct-injected engine, initially available for the Civic in Asia and Europe. BorgWarner’s compact turbocharger improves engine efficiency and boosts performance, helping achieve an outstanding power output of 95 kW (127 HP) with quick engine response.
“Designed for powerful, downsized engines, BorgWarner’s wastegate turbocharger combines high power density and excellent response in an extremely compact package,” said Frédéric Lissalde, President and General Manager, BorgWarner Turbo Systems. “BorgWarner’s first global development with Honda reflects our strong reputation as a leading supplier of advanced turbocharging technologies and supports our growth in Asia and around the world.”
BorgWarner’s reliable B01 turbocharger features a compact, robust design with low noise, vibration and harshness and facilitates the use of low viscosity oil. Its advanced materials withstand exhaust temperatures up to 950 degrees Celsius and rotational speeds of up to 285,000 rpm. Fitted with an electrically actuated wastegate for highly accurate control to prevent charge pressure at high engine power, BorgWarner’s turbocharger delivers powerful and efficient performance. In addition, it improves fuel economy while providing excellent torque characteristics over the entire engine speed range. The low-inertia turbine wheel allows a wider performance range while optimized harnessing of exhaust gas pulsation offers fast response at low engine speeds. In addition, the rapid activation of the catalytic converter during cold starts significantly reduces emissions.
GM announced both automakers have invested $85 million total into a joint fuel cell manufacturing operation in Michigan. The operation, titled Fuel Cell System Manufacturing, LLC, will operate within GM’s existing battery pack manufacturing facility site in Brownstown, Michigan. Both automakers are planning to mass produce fuel cells at the facility beginning in 2020.
Both GM and Honda will continue to share what it learned through its fuel cell engineering and operations and place the technology in future roadgoing vehicles. This work will ultimately lead to the next generation of fuel cells and hydrogen storage technologies and create a more affordable commercial solution for fuel cell and hydrogen storage systems.
“The combination of two leaders in fuel cell innovation is an exciting development in bringing fuel cells closer to the mainstream of propulsion applications,” said Mark Reuss, GM executive vice president, Global Product Development, Purchasing and Supply Chain. “The eventual deployment of this technology in passenger vehicles will create more differentiated and environmentally friendly transportation options for consumers.”
GM and Honda have led the fuel cell technology space for years with 2,200 patents between both automakers. The upcoming operations are expected to add 100 jobs to the Brownstown battery facility.