innovations for eco-friendly mobility - eberspaecher · innovations for eco-friendly mobility...

E x H a u s t t E c H n o l o g y | PA S S E n G E r C A r

I n n o V A T I o n S F o r E C o - F r I E n d l y m o b I l I T y

d r I V I n G T H E m o b I l I T y o F T o m o r r o w

2 | E x H A u S T T E C H n o l o G y P A S S E n G E r C A r

ProduCTIon oF CommErCIAl VEHIClE SySTEmS*:Euro 3 commercial vehicles 199,000Euro 4 + 5 commercial vehicles 130,000

CorE CuSTomErS For PASSEnGEr CAr ExHAuST TECHnoloGy*:Audi, bmw, FIAT, land rover, mercedes-benz, opel, Peugeot/Citroën, Porsche, renault/nissan, Saab, Vw

dATA on EbErSPäCHEr ExHAuST TECHnoloGy*:Turnover in Eur 1.93 billionnumber of sites 35number of countries 22number of plants 22Employees 4,284

ProduCTIon oF PASSEnGEr CAr SySTEmS*: Complete systems 2,122,000Catalytic converters, diesel particulate filters, manifolds 2,258,000Sd systems 536,000 * As of 2008

E x H A u S T T E C H n o l o G y P A S S E n G E r C A r | 3

Environmentally-friendly technologies are increasingly becoming a key criterion in the automotive market. Manufacturers who already

comply with the statutory limits of the future will guarantee themselves an important lead over their competitors. And the fact that

requirements on emission control will continue rapidly to become more and more rigorous is beyond doubt – especially in view of the

growing level of mobility in the emerging areas of Asia and South America. Eberspächer has been aware of this challenge for a long

time. As one of the world's leading specialists for exhaust systems, we help vehicle manufacturers throughout the world to achieve

their ambitious aims.

For dEmAndInG rEquIrEmEnTS on low EmISSIonS

Advanced technology is a tradition at Eberspächer. As early as

1932, we won a muffler competition in Paris – and since then we

have constantly striven for innovation. However, the requirements

have increased enormously since then. In situations where a simple

muffler used to serve the purpose, sound design is now required.

And the basic exhaust pipe from days gone by has long since

become a complex "emissions purification plant". with our exhaust

systems, we make an active contribution to more eco-friendly

mobility throughout the whole world. we are involved in all the key

markets in Europe, America and Asia in order to work closely with

our customers to meet the challenges presented by increasingly

stringent environmental standards.

FoCuSEd on THE FuTurE:

Perfect mechanical, thermal and chemical coordination of the

various components in an exhaust system and the engine – this

is the secret of the success of the Eberspächer exhaust specia-

lists. Currently, considerably more than 90 % of pollutants can be

eliminated using modern system technology. And noise emissions

are also reduced dramatically. However, rapid progress still has

to be made.

we therefore invest an average of 7 % of our net turnover in global

development activities. And our on-going product and process op-

timization work ensures attractive unit costs – which our customers

appreciate as much as the quality of our products and the strong

partnership philosophy which characterizes our company more than

virtually any other.


dynAmIC APProACH To THE FuTurE:

There is no doubt that what we have achieved so far with respect

to reducing pollutants and noise is something to be proud of.

However, the automotive industry does not stand still – and the next

demanding challenges have already been defined. The automotive

manufacturers have committed themselves to continuing to reduce

the average Co2 emissions drastically. diesel vehicles are becoming

increasingly popular and even more effective methods for reducing

the emissions of soot particles and nitrogen oxide are needed. we

have accepted the challenge.

InnoVATIVE mETHodS For dEVEloPInG nEw ConCEPTS:

Innovation is the Eberspächer corporate principle. more than 360

highly-qualified engineers and technicians work in our own ideas

factories – or often on-site with the customer – on the future of the

car. when new technologies are designed, we use the same modern

CAd systems as our customers – supplemented by simulation and

computing programs. The precision of these programs enables us to

optimally prepare our solutions in line with actual usage.

And we also rely on state-of-the-art manufacturing methods at our

production facilities. The creation of "Centers of Competence" has

generated a new dynamic with respect to process innovations. we

have developed new solutions for canning, automation, forming and

joining technologies in order to continue to make our contribution

as a leader in new technologies in the world of the automobile in

the future.

no ComPromISES wITH quAlITy:

All the work carried out by Eberspächer departments is based on

a quality management system which corresponds to the TS 16949

global standard and which is steadfastly committed to the zero

defect strategy. Furthermore, all Eberspächer plants are certified

according to ISO 9001, QS 9000, VDA 6.1 and ISO 14001.

And numerous quality awards from the vehicle manufacturers

themselves provide proof that we are on the right track with our

performance philosophy.

bEnEFITS oF modErn EbErSPäCHEr ExHAuST TECHnoloGy:

Functions achieved reliably

Innovative solutions for required space, weight,

back pressure and acoustics

Proven durability

Very cost effective

Our customers want to achieve a great deal – and, as a high-performance partner, we would like to play a major part in constantly

giving new impetus to technological advances. Approximately 20,000 exhaust systems developed and around 1,200 valid patents –

these figures alone are testament to our on-going success in the field of exhaust technology. And in the future we will continue to

be spurred on by one thing in particular – the driving force of innovative ideas.

InnoVATIon IS our drIVInG ForCE


EbErSPäCHEr In CloSE ProxImITy To ITS CuSTomErS –

In numErouS CounTrIES

Fashioning the future. On a global level. Protecting the environment is a challenge that knows no boundaries. Therefore vehicle

manufacturers the world over rely on close, on-going cooperation with the exhaust specialist Eberspächer. In numerous countries,

Eberspächer provides support directly at its customers' production facilities. And approximately half of the total Eberspächer turnover

is attained with exports or production abroad.

TAIlor-mAdE CuSTomEr orIEnTATIon For TECHnoloGy:

Every Eberspächer exhaust system is custom-made. Close coopera-

tion with the customer is therefore very important – at international

level too. Approximately 2,130 Eberspächer employees work

abroad. Global just-in-sequence supply to the final assembly line

has already been implemented in many countries. In addition to

the main plant in neunkirchen with more than 1,900 employees,

the global Eberspächer production network includes sites in Europe,

Asia and north and South America. These sites are supplemented

by our development centers in Esslingen and detroit, plus various

engineering offices with resident Engineers. In this way we ensure

that even in the very early product development phases, every

aspect meets the customer requirements.

on-GoInG CommITmEnT:

The automotive industry is meeting global challenges with re-

gional production and development facilities – and Eberspächer

is determined to support this development on a worldwide basis.

our international presence is being continually – and systemati-

cally – extended. we are implementing on-going, global activities

in development and in production – e.g. in Korea and Japan and in

the emerging markets of brazil, russia and China. on a 5,000 m² site

near Pune in India, 120 employees have been producing exhaust

systems, mufflers and catalytic converters since April 2009 – a total

of 750,000 parts per year. In the affiliated development center, the

engineers benefit from state-of-the-art work stations. These cross-

border cooperations and joint ventures provide important impetus

for the future – and bring Eberspächer know-how even closer to

the customer.

India USA


E x H A u S T T E C H n o l o G y

T h e A m e r i c A s e u r o p e A s i AA f r i c A

b r A z I lS ã o b e n t o d o S u l

C A n A d Ab r a m p t o n

u S An o v i

b r i g h t o n

T u s c a l o o s a

G E r m A n yE s s l i n g e n

n e u n k i r c h e n

E m d e n

m u n i c h

u n n a

F r A n C EP a r i s - E l a n c o u r t

S t . m i c h e l

m a u b e u g e

G r E A T b r I T A I nC o v e n t r y

I T A lyT u r i n

C a s t e l l a l t o

C H I n Ad a l i a n

C h a n g c h u n

I n d I AP u n e

J A P A nT o k y o

K o r E AS e o u l

A u S T r I AG r a z

r u S S I Am o s c o w

S w E d E nT r o l l h ä t t a n

C z E C H r E P u b l I Cr a k o v n i k

S o u T H A F r I C AP o r t E l i z a b e t h

E a s t l o n d o n

P r e t o r i a

South Africa Central Germany


Without an ideal development infrastructure, it would be impossible to meet our standards concerning the quality of our products. There-

fore we pay extremely close attention to creating optimum conditions and utilizing state-of-the-art technology and systems in all areas.

oPTImum InFrASTruCTurE For dEVEloPmEnT

dESIGn:

Each new exhaust system that is developed is tailor-made to the

packaging space available in the relevant vehicle/engine. State-of-

the-art CAd systems are used for this purpose, which also form the

basis of simulations.

ACouSTICS:

The acoustic set-up firstly ensures that statutory requirements are

complied with. Secondly, it is a key factor for the subjective sound

characteristics (dnA) of the vehicle. The sound design is primarily

achieved by means of simulation programs and verification in

appropriate sound studios. Finally, validation is performed on

modern engine and vehicle roller test benches.

THErmodynAmICS:

In order to optimize the flow and reduce thermal loss or the surface

temperature, modern computer technology is used once again.

Engine and emission test benches are available for testing finished

parts under actual operating conditions.

durAbIlITy:

The service life of an exhaust system is a considerable challenge

for our specialists in the durability departments and material labs.

using modern simulation methods and test facilities, we arm our

products against thermal, mechanical and chemical attack.

GlobAl dEVEloPmEnT nETworK:

Eberspächer has a global development network comprising an r&d

center at the headquarters in Esslingen, a d&d center in detroit,

mI, uSA and several engineering offices (brazil, France, Italy, Great

britain, India, Korea, Japan). All the tools and methods needed to

develop exhaust systems according to the Eberspächer design &

development handbook are available at every site.


ConSTAnT ProGrESS In ProCESS TECHnoloGy

In addition to ideal conditions for development activities, we also ensure constant progress and the implementation of the most up-to-

date innovations in the area of process technology. Extremely flexible plant engineering and state-of-the-art simulation options therefore

facilitate an exceptionally high degree of process reliability and optimum use of materials.

CEnTErS oF ComPETEnCE:

In order to meet the technological demands of the future,

Eberspächer has reorganized its technology sector.

The following issues are our focal points

developing new technologies for all high-tech plants within the

group

developing suitable technologies for all emerging markets

and low cost countries – modified, requirements- oriented

technology for these special locations

developing globally-applicable technology standards

Global consultation and support for the developments with

respect to the most up-to-date processes, in cooperation with

the oEms

leadership in exhaust technology

In order to achieve these ambitious aims, the technology segment

has been divided into four different areas.

1. "CAnnInG" TECHnoloGy ArEA:

This area deals with all the production processes involved in can-

ning as well as the integrated assembly sequences. In addition to

the various canning processes, we have recently developed and

implemented a high-quality, unique procedure for a long-standing

customer – the "mono drill process". The advantage of this process

is the absolute precision of fit of the parts to be drilled (jacket

housing, mounting mat and honeycomb) and the measuring options

within the honeycomb, without any more space being taken up by

the additional gap between two honeycomb elements.

2. "AuTomATIon" TECHnoloGy ArEA:

Smaller and smaller lot sizes and the increasing variety of versions

demand new technologies – and the highest possible degree of

efficiency. At Eberspächer, automated measurement methods with

networked processes ensure a constant exchange of information

between the individual machines and production lines. deviations

from the target status are detected and corrected while the process

is still running. This facilitates a considerable reduction in start-up

wastage at the beginning of production and of the set-up costs on

the machine. The throughput time of an order is also shortened.

3. "FormInG" TECHnoloGy ArEA:

"weight reduction" is currently one of the most important demands

that the oEms are placing on the supply industry. In order to respond

to this issue, various concepts are currently being developed e.g.

the various different tailored processes (tailored tubes, tailored

stripes) as well as the use of new materials (e.g. titanium) – with ever

more complex geometries. This development process is supported

by state-of-the-art simulation technology.

4. "JoInInG" TECHnoloGy ArEA:

Smaller and smaller material wall thicknesses in conjunction with

new materials and material combinations, coupled with ever in-

creasing component stresses – all this without a detrimental effect

on quality. In the joining technology area, Eberspächer is currently

working on the "laser hybrid process", a combination of laser and

mIG welding processes. less energy input, faster welding speed and

a higher degree of process reliability are the obvious advantages of

this new technology.

1 0 | E x H A u S T T E C H n o l o G y P A S S E n G E r C A r

ToP-ClASS quAlITy ASSurAnCE And ProduCTIon

Our aim is for our customers to experience the same quality standards that guarantee our high product quality at all Eberspächer

sites. We have organized our quality systems based on this objective.

CEnTrAl quAlITy mAnAGEmEnT:

The Eberspächer quality standards are developed in the central

quality management department. This includes globally consistent

problem-solving methods such as "drill deep" and "Fast response",

standardized testing concepts and basic, design and process FmEAs

to ensure successful new product launches. Adherence to the

standards is monitored globally via a central auditing program.

CuSTomEr quAlITy oFFICEr:

we have appointed quality officers for each customer who ensure

that all quality-specific customer expectations are met – during the

project and during series production.

wArrAnTy – lESSonS lEArnEd:

In order to obtain systematic information about our products in

the field throughout the world and to use this for new projects, a

central warranty office has been set up in neunkirchen. Cross-

location processes have also been introduced for this purpose.

Our global standards are developed on an on-going basis at our

annual quality conferences.

SuPPlIEr mAnAGEmEnT For dEVEloPInG A quAlIFIEd, SuSTAIn-

AblE SuPPlIEr bASE:

optimum supplier management is achieved at Eberspächer by in-

volving the supplier in our program management system at an early

stage. working in partnership, innovative and cost-optimized

products are developed for the customer and the best possible

supply chains for JIT deliveries are worked out.

new suppliers are assessed by a team of experts and they undergo

systematic qualification with respect to customer requirements and

Eberspächer specifications. The ability to be innovative, globality,

process capability and reliability are the key selection criteria.

A comprehensive risk analysis provides evidence of the capability

of the new supplier.

Targeted further development of series production suppliers, based

on supplier assessments and global "benchmarking", ensures that

the supplier portfolio is continually improved in terms of quality,

delivery performance and costs.

"bEST In quAlITy" In ExHAuST TECHnoloGy:

The factors which contribute to our success are

EPM Eberspächer process management system: Standardized

quality processes at all sites.

PM program management system: Standardized forward planning

for quality and "gate" approvals in all customer projects.

4E-KPI quality control system: Stringent monitoring of the quality

data (delivery performance, rejects …) to improve the process

performance as well as to facilitate competition between the sites.

4F quality offensive at all production facilities: The Eberspächer

4Fphilosophy involves effective fault prevention based on targeted

fault detection, rigorous fault analysis and long-term fault

elimination. This raises every employee's awareness: "We must

produce quality."

E x H A u S T T E C H n o l o G y P A S S E n G E r C A r | 1 1

Eberspächer is aware that we can only meet the high quality standards of the customer and the enormous cost pressure from the com-

petition using up-to-date technologies and machines.

FlExIblE ProduCTIon oF CATAlyTIC ConVErTErS:

Canning is the art of attractive packaging. However brute force

cannot be used as the porous ceramic honeycombs for catalytic

converters and diesel particulate filters are extremely easy to

damage due to their delicate structure. As opposed to the traditional

canning process, Eberspächer uses high-tech processes to meet

the stringent quality and cost requirements of our customers. The

Eberspächer group uses fully-automatic procedures within the

canning process.

For the production of underhood catalytic converters, Eberspächer

uses highly-flexible, modern production lines.

The process sequence begins with supplying the blanks and end

cones for the finished catalytic converter can.

After the blank has been separated off, it is rolled. Then it is welded

and calibration and pressing work is carried out at the same time.

The subsequent canning process is de-coupled by means of an

intermediate buffer for the cans. The newly defined tandem canning

process features a high level of performance with respect to quality

and quantity.

within the system, the ceramic honeycombs are "paired up" with

the mounting mat and they are pre-positioned via a shuttle. The

subsequent canning process assembles the ceramic, the mounting

mat and the can together. Integrated labeling is then performed to

meet the traceability requirements of our customers.

If substrate or mat properties have to be changed when the project

is up and running, our flexible system technology enables the

necessary process modifications to be made. A high degree of

canning and operational reliability is still ensured.

FlExIbIlITy In ProduCTIon – For A HIGH dEGrEE oF rElIAbIlITy


mArKET TrEndS/TECHnoloGy roAdmAP – wHAT wIll THE mobIlITy oF THE FuTurE looK lIKE?

2008 2028

Fuel cell > 1 %

battery electric vehicle 3-5 %

range extenders 10 %

Full hybrids/mild hybrids 15 %

Alternative fuels 25 %

Combustion engine 45 %

95 %


SoluTIonS And InnoVATIonS For THE PrESEnT ...

In future, more and more demanding requirements will be placed on exhaust technology. Packaging, acoustics, thermodynamics,

durability, a variety of versions, shorter development time, cost savings – all these factors are decisive for ensuring our success and

that of our customers. Therefore we are constantly working on optimizing our development methods and designing new, innovative

and highly effective solutions.

nEw ProduCTS For FuTurE ExHAuST EmISSIon STAndArdS:

Increasingly lower pollutant limits require ever improving exhaust

technology. Eberspächer currently develops combined systems and

components – e.g. a fuel processor as well as swirl and mixing

elements – with which the following objectives can be achieved.

Fast catalytic converter light-off

Temperature management for SCr catalytic converters with urea

injection

uniform particulate filter regeneration under all

operating conditions

uniform urea application on the catalytic converter

uniform flow from combined systems comprising oxidizing

catalytic converter, particulate filters and SCr catalytic converter

lIGHT-wEIGHT dESIGn To ComPly wITH FuTurE Co2 lImITS:

The exhaust system can play a major part in reducing the vehicle

weight. In a framework project, Eberspächer has therefore investi-

gated the potential for reducing the wall thickness of all individual

parts, whereby tailored blanks were used as muffler casings and

tailored tubes as intermediate tubes. This produced a weight

advantage of more than 25 % or 10 kg for the entire system. The

resultant consumption benefit can be converted into a reduction

of CO2 emissions of approx. 0,7 g/km. The functions, durability and

the suitability for use in large production series are also ensured.

SCr CATAlyTIC ConVErTEr SySTEmS – mIxInG ElEmEnTS

ImProVE EFFICIEnCy:

The SCr systems from Eberspächer operate with urea as a reduc-

ing agent. due to the heat in the exhaust pipe, ammonia is pro-

duced from the urea. This reacts in the SCr catalytic converter with

the nitrogen oxides and converts them to nitrogen and water vapor.

The urea is injected as an aqueous solution into a special exhaust

pipe with a mixing function, upstream of the catalytic converter.

when the aqueous urea solution is injected upstream of the catalytic

converter, the mixing element, positioned behind the injection

point, takes on two important roles. It ensures that the aqueous

urea solution is distributed homogeneously in the exhaust stream

and it encourages vaporization of the urea/water droplets due to

the additional surfaces in the exhaust stream. both of these effects

combine to increase the efficiency of the SCr catalytic converter.

SwIrl ElEmEnTS For InCrEASEd EFFICIEnCy oF CATAlyTIC

ConVErTErS And PArTICulATE FIlTErS:

Exhaust gas flow is broadened in relation to the mass flow by means

of a swirl element upstream of the catalytic converter. In this way –

depending on the arrangement of the catalytic converters – a more

uniform distribution of the exhaust stream and a more homogenous

temperature distribution in the catalytic converters can be achieved.

The flow to the particulate filter is also more uniform, the filter

is subject to a more even load and therefore it regenerates more

homogeneously. Furthermore, the ash is also distributed more evenly

in the filter ducts. The advantage being that the pressure loss in the

filter increases more slowly throughout its service life.


... And For THE FuTurE

FuEl ProCESSor – For ACTIVE, EnGInE-IndEPEndEnT THErmAl

mAnAGEmEnT For ExHAuST EmISSIon TrEATmEnT:

The fuel processor is an innovative concept, which combines the

burner and the HC doser in a single component. However the fuel

processor has one additional function that the burner does not

have – partial combustion. when the fuel is supplied it is completely

vaporized and partially oxidized. This counteracts the typical

disadvantage of the HC doser – droplet formation in the exhaust

system. The relevant operating modes, regulated individually by

a control unit via a map, facilitate the following:

Faster oxidizing catalytic converter light-off

Active regeneration of the particulate filter

Thermal management for the SCR catalytic converter

Active regeneration of NSC systems (NOX storage catalyst)

The advantages are obvious:

Clear potential for saving fuel and reducing emissions

No engine post-injection

No oil dilution

Possibility for more frequent regenerations

Smaller filters

More reliable operation with lower-cost cordierite filters

As regeneration can always be completed reliably, partial regenera-

tions can be avoided.

lATEnT HEAT ACCumulATor CATAlyTIC ConVErTEr – For A

low-EmISSIon Cold STArT duE To THE uSE oF rESIduAl

EnErGy And HEAT:

Current catalytic converter systems work from a substrate tempera-

ture of approx. 180 - 200 °C. Therefore the cold start phase until the

catalytic converter light-off has been attained makes a considerable

contribution to the emissions during the driving cycle. A heat ac-

cumulator integrated into the exhaust system to store the exhaust

heat generated during normal driving makes thermal energy avail-

able for subsequent cold start phases.

Eberspächer is working on the development of a latent heat accumu-

lator such as this. A special storage medium with a melting point of

approx. 250°C is introduced into the catalytic converter. The melting

process, breaking open the crystal structure and the transition into

a liquid phase binds very large amounts of heat. As the process is

reversible and the heat is emitted again when the substance returns

to its solid state, the process is ideal for storing heat. In this way the

catalytic converter maintains its operating temperature even when

the vehicle is stationary for long periods (e.g. over night) and it can

therefore work when the engine is started without a time delay.

The cold start emissions are reduced to a fraction of the normal

value. As the stored heat comes from exhaust heat, this process is

Co2 neutral, in contrast to other catalytic converter heating strate-

gies. The technology can also be used in hybrid vehicles. In this

case, the latent heat accumulator keeps the catalytic converter at

operating temperature while the vehicle is running on electricity in

order that the converter can work straight away when the combus-

tion engine is subsequently started.


ACTIVESIlEnCE SySTEm From EbErSPäCHEr

The principle of eradicating unwanted sound waves by using intentionally generated "antiphase" sound waves has been patented since

1933. However, the effect only began to be used for technical purposes in the 1980s – e.g. for sound deadening headphones for pilots.

AnTI-Sound And Sound dESIGn – noT A ConTrAdICTIon In TErmS:

In principle, anti-sound is also suitable for use in mufflers. However

two factors have prevented it from being used effectively up until

now – the ambient conditions inside the exhaust systems and

the quickly changing engine speeds and loads on the engine. The

high-performance, cost-effective sound transducers (ActiveSilence

system) developed by Eberspächer have made significant advances

in this area. Another problem has been solved by means of innova-

tions in the field of electronic computing technology – the required

controller hardware has now become so small and powerful that

it can, for example, be integrated into conventional engine control

units.

In addition to eliminating sound waves – i.e. pure sound attenuation –

the ActiveSilence system is also capable of enhancing certain fre-

quencies (engine orders) in order to achieve the required sound

quality (sound design). As opposed to conventional exhaust systems

with passive mufflers, this means that exhaust noises can be

adapted to the vehicle or the driving situation by means of software

Amplifier

Enginecontrol unit

ActiveSilencecontroller

Catalytic converter

Engine

ActiveSilencesystem

Error microphone signal

Control signal

Sound Anti-sound Eliminated sound

Engine

Amplifier

settings alone. In the pre-development phase, the ActiveSilence

system has already been successfully tested on 4, 6 and 8-cylinder

engines.

bEnEFITS For ACTIVE Sound dESIGn:

modified, custom-made sound design

Individually programmable sounds (comfort, sport etc.)

reduction/elimination of frequencies/engine orders

Enhancement of frequencies/engine orders

back pressure reduction (fuel consumption)

weight reduction (fuel consumption)

THE FollowInG rEduCTIonS HAVE bEEn VErIFIEd: muffler volume: up to 60 % weight: up to 40 % approx. 1g Co2/km back pressure: up to 150 mbar 2g Co2/km

Total: up to 3g Co2/km or 226,800 tons of Co2 per year*

* 15 % of the passenger cars in Germany (42 million cars in 2008) with an annual driving distance of 12,000 km.

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Headquarters:

J. Eberspächer GmbH & Co. KG

Eberspächerstrasse 24

73730 Esslingen

Phone: +49 711 939-00

Fax: +49 711 939-0634

[email protected]

www.eberspaecher.com

innovations for eco-friendly mobility - eberspaecher · innovations for eco-friendly mobility...

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