- Advanced exhaust gas recirculation (EGR) cooler is said to help heavy-duty on-highway engines meet 2010 emissions regulations.
- Centrifugal electro-hydraulic (CEH) actuator is said to help improve fuel economy while delivering torque management performance for all-wheel drive systems in a compact, integrated system.
- Turbocharger with low-pressure EGR is said to significantly improves fuel economy, reduces emissions and improves engine response for diesel engines.
“To benefit customers as well as the industry, technological innovations must provide automakers with fast-to-market solutions to real-world challenges. BorgWarner’s focus on improving fuel economy, reducing emissions and enhancing performance is helping engines become more powerful, efficient and environmentally friendly and enabling all-wheel drive systems to deliver better handling without compromising fuel economy,” says Timothy M. Manganello, chairman and chief executive officer, BorgWarner. “We are proud to add to our long history of innovation with our latest advancements and honored to be among this year’s distinguished PACE finalists once again.”
BorgWarner’s advanced EGR cooler is comprised of two separate heat exchanger cores running off of two engine coolant circuits. The modular design is said to deliver superior heat rejection with less soot and hydrocarbon buildup in a compact, production-friendly package. Specially designed hybrid tubes optimize heat transfer, while a floating core features baffles to optimize coolant flow, protective bushings to tolerate extreme thermal stresses and anti-vibration clips to withstand the severe vibration loads expected in heavy-duty inline engines, the company says.
Using a hydraulic power pack, BorgWarner’s CEH actuator is said to eliminate several costly and complex parts. Fewer parts result in lower costs, 20 to 30 percent less driveline mass than comparable technologies, and improved fuel economy. Driven by an electric motor, an axial pump with a patented centrifugal pressure regulator directly controls hydraulic pressure to the all-wheel drive clutch. The actuator also features an automatic recalibration function that re-adjusts the system without any input from the driver. The CEH actuator is expected to debut in 2012.
Diesel engines provide fuel efficiency, but meeting low emissions requirements is a challenge, BorgWarner says. While EGR is proven to reduce emissions, only high-pressure systems have been available because turbochargers were unable to withstand extreme loads and damaging particles inherent in low-pressure systems. BorgWarner developed coatings to protect turbocharger compressor wheels and other components from the abrasive and corrosive particles. By comprehensively optimizing the combustion process and increasing EGR rates, the turbocharger not only reduces emissions, but achieves better engine response and fuel economy, the company says.
The PACE Awards honor superior innovation, technological advancement and business performance among automotive suppliers.
