turbocharging systems for passenger cars

8/6/2019 Turbocharging Systems for Passenger Cars

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by technology

Turbocharging Systems for Passenger Cars


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Although its been over a hundred years since

the automobile was invented, the technological advances

being made today are producing more surprises than

ever. In serving the automotive industry, BorgWarner

Turbo Systems is right in the vanguard of these devel-

opments with forward-looking concepts, products

and solutions that meet real market needs.

The requirements that have to be met in build-

ing passenger cars today are diverse and the demands

are steadily increasing. High standards of safety and

comfort are a must, but thats not all. Low fuel consump-

tion, minimal pollutant emissions, durable quality, and

long life are also essential. And further down the road,

you can expect the challenges to keep on growing.

In particular, its crucial to continue developing

better engines. And turbocharging holds enormous

potential for clearing many of the hurdles involved.

The challenges are magnified by the need to

get new products to market faster. This makes it more

important than ever for engine developers to cooperateclosely with parts suppliers.

No one is more acutely aware of these needs

than we are. We therefore offer you considerably more

than the best possible products. Were also committed

to helping you get your new engines and vehicles to

market more quickly than ever. To achieve this, we work

with you intensively to optimize product development

processes and secure you a decisive competitive edge

in the marketplace.

Enabling your success is a challenge that we

welcome. Count on us to meet your needs. From our

companys top management down to every single

employee, were dedicated to serving you. For the mar-

ket and the engines of tomorrow.

T h e C h a l l e n g e s

A r e G r o w i n g .

A n d w i t h u s , s o w i l l

y o u r s u c c e s s .

BorgWarner Turbo Systems is a

technological leader offering turbo-

charging systems for both gasoline

and diesel engines.

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Turbocharging is playing an increasingly vital role

in developing engines for today and tomorrow. But to

ensure perfect interplay of all c omponents, we have to

work together very closely. Which is why we do every-

thing we can at BorgWarner Turbo Systems to efficiently

and effectively support you.

To deal with todays highly complex technolo-

gies and meet the need to develop products faster and

faster, we set up project groups devoted specifically to

achieving your aims. These then cooperate closely with

your own teams. We even go as far as assigning resi-

dent engineers to your facilities, where they provide you

with constant on-site support.

We make a point of putting together our pro-

ject teams so theyll work as competently and quickly as

humanly possible to achieve their and your goals.

This starts right in the initial phase of engine develop-

ment. Seasoned application engineers with in-depth

knowledge of combustion and turbocharging technolo-

gy get together with experienced designers, backed by

manufacturing, purchasing, quality control, and devel-

opment specialists.

The ability to exchange product data fast and

completely with you is another vital requirement for suc-

cessful cooperation. So in addition to advanced devel-

opment tools, when expedient we install and use the

same IT systems as you to ensure seamless cooperation

based on consistent data models and smoothly conduct

our cross-company projects.

W h e r e v e r Y o u A r e ,

W e l l C o m e t o Y o u .

B u t e v e n m o r e i m p o r t a n t i s o u r

c o m m i t m e n t t o p u t t i n g y o u f i r s t .

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Ultra modern developing procedures

such as Rapid Prototyping reduce

developing time and cut costs.

In addition to ProEngineer, we use the

same development systems as you.

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Being a key technology, turbocharging calls for

a high level of kn ow-how, competence, and innovative-

ness. That is why BorgWarner Turbo Systems has con-

sistently attached high priority to development.

High quality of our employees, innovation

potential and a wide variety of alliances render BW TS

a competent partner in the automotive indus try. We

offer a dialogue to our customers which may be decisive,

in terms of competition, for the development of future

engine concepts. This is why many of our customers

ask for our advice already at the i nception phase, not

only when series production is due to start. We thus

achieve optimal results.

To support you and boost our innovative ability,

we have established one of the worlds most advanced

turbocharger development centers. Its state-of-the-artengine and gas test rigs, high-end CAD systems, and

cutting-edge simulation tools help make BW TS the

development partner of choice for many vehicle manu-

facturers.

BorgWarner Turbo Systems keeps setting

new standards with innovative solutions. You too can

benefit from our broad expertise on turbocharging

products and systems. Massed knowledge that we like

to put at our customers disposal.

A G o o d S u p p l i e r

T h i n k s f o r Y o u .

A b e t t e r s u p p l i e r

t h i n k s a h e a d .

Complete systems, turbochargers with electric actuators, turbochargers

able to withstand 1050C, the eBooster: solutions from BW TS help

drive progress in engine development.

Cutting-edge test stands are deployed

to optimize the interplay of engines and

turbochargers.

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BorgWarner Turbo Systems strives for product

leadership. Therefore we not only develop turbocharging

systems, but also optimally adapt them to meet your

needs. Our goal is to find ideal solutions for you. In terms

of technology, quality, and processes.

In the passenger car category, BW TS offers

you several ranges for diesel and gasoline engines

that have proven themselves in practice millions of times

over. To supplement these turbocharging sys tems, you

can draw upon a broad range of standard, optimally

harmonized compressors and turbines, as well as differ-

ent control systems. No matter what your specifications

are BW TS has the right technology.

Our offering includes turbochargers with vari-

able turbines for diesel and gasoline engines. An absolute

innovation are multistage, regulated turbochargingsys-

tems. These include the regulated, two-stage turbo-

charging R2S and the eBooster system, in which

an electrically driven centrifugal compressor supports

the turbocharger.

Increasingly, turbochargers with high tempera-

ture resistance are in demand. Responding to this need,

BW TS was the first to develop a range of products

designed specifically for extremely high temperatures

up to 1050C. At the same time, we have also met the

industrys most stringent requirements and set new

standards for high-performance, extremely low-emission

engines with low fuel consumption.

W e O f f e r M o r e T h a n

S t a n d a r d S o l u t i o n s :

S o l u t i o n s t h a t

s e t n e w s t a n d a r d s .

T u r b o c h a r g i n g S y s t e m s

f o r G a s o l i n e E n g i n e s :

Special requirements for diesel engines:

High efficiency Broad compressor maps Flexible, precise control

Dynamic response Flexible design Compact packaging

Our Solutions:

New turbine and compressor generations to maximize specific engine outputVTG range with different frame sizes and performance classes

Regulated, two-stage turbocharging R2S

Various control options with pneumatic and electric actuators

Special design solutions depending on the available space, e.g., with integrated components such

as exhaust manifolds and other parts

T u r b o c h a r g i n g S y s t e m s

f o r D i e s e l E n g i n e s :

Special requirements for gasoline engines:

Temperature resistance up to 1050C High efficiency Broad compressor maps

Flexible, precise control Dynamic response Flexible design

Compact packaging

Our Solutions:

Specially developed range: Special designs High-quality materials Water-cooled bearing housings Enhanced systems for high-temperature applications up to 1050C

New turbine and compressor generations

Different turbocharging concepts for different engine strategies: Boost pressure control flaps and valves

Variable turbines Twin-entry turbine housings eBooster

Special design solutions depending on the available space, e.g., with integrated components such

as exhaust manifolds and other parts

Engine Performance dependent on TC-Frame Size Engine Performance dependent on TC-Frame Size

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BW TS offers a wide

selection of turbochargers

for the output range be-

tween 20 and 250 kW: our

KP, K0, K1 and K2 series.

They can be adapted to dif-

ferent engine types, installa-

tion requirements and per-

formance requirements, and

equipped with additional

components as needed.

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Range KP K 0 K 1 K 2

Frame Size KP 31 KP 35 KP 39 K 03 K 04 K 16 K 24

Mass Flow (kg/s) 0,09 0,12 0,14 0,17 0,21 0,26 0,30

Output Range (kW) 65 80 100 120 150 175 200

Wastegate

VTG

VST

Range KP K 0 K 1 K 2

Frame Size KP 39 K 03 K 04 K 16 K 24

Mass Flow (kg/s) 0,14 0,17 0,21 0,26 0,30

Output Range (kW 120 150 185 220 250

Wastegate

VST

Twin-Entry Turbines

1050C technology


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At BorgWarner Turbo Systems, all of our pro-

duction processes are geared to your needs. We have

the flexibility it takes to produce either small, highly

tailored series or high volumes with fewer versions. This

strategy gives you the freedom you need.

Right from the start of the development

process, we take manufacturing considerations into

account. We involve and consult those responsible for

project planning, purchasing and production to optimize

major sections of the automotive industrys value chain.

Our goal is to perfectly harmonize all routines to save

time and costs.

Our highly modern production systems are

naturally also matched by the approach we take to work.

Interdisciplinary teamwork is a matter of course, and all

participants take full responsibility for their products

and processes. Our efforts focus on continually improv-

ing processes and developing new production methods

and processes. Especially for launching the latest prod-

uct technologies, we pay great attention to perfecting

the required manufacturing methods at the same time.

All these activities yield significant competitive

advantages for you: quality and flexibility. Quality man-

agement at BorgWarner Turbo Systems is exemplary,

as proven by certifications under ISO 9001, QS 9000

and VDA 6, and most convincingly by our growing suc-

cess and the satisfaction of our customers.

W e D o n t J u s t

T e s t f o r Q u a l i t y .

W e d e s i g n f o r i t

f r o m t h e s t a r t .

In addition to delivering products with the

quality BorgWarner Turbo Systems is

famous for, we design efficient, cost-opti-

mized production processes.

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BorgWarner Turbo Systems

Worldwide Headquarters GmbH

Marnheimer Strae 88

67292 Kirchheimbolanden/ GermanyPhone: ++49 (0)63 52 75 3-0

Fax: ++49 (0)63 52 75 3-99

BorgWarner Turbo Systems GmbH

Marnheimer Strae 85/ 87

67292 Kirchheimbolanden/ Germany

Phone: ++49 (0)63 52 4 03- 0

Fax: ++49 (0)63 52 4 03-1866

BorgWarner Ltd.Euroway Industrial Estate

Bradford BD4 6SE

West Yorkshire/ UK

Phone: ++44 12 74 68 49 15

Fax: ++4412 74 68 9671

BorgWarner Turbo Systems

PO Box 15075

Asheville, NC 28813/ USA

Phone: 001 828684 40 00

Fax: 00 1 828684 4114

BorgWarner Brasil Ltda.

Estrada da Rhodia Km 15

P.O. Box 6540

13084-970 Campinas-SP/ Brasil

Phone: ++55 19 37 87 5700

Fax: ++55 1937 8757 01

Hitachi Warner Turbo Systems Ltd.

3085-5 Higashi Ishikawa Saikouchi, Hitachinaka-shiIbaraki-ken

312-0052, Japan

Phone: +81(0)29 -276 -93 88

Fax: +81(0)29 -276 -93 97

www.turbos.bwauto.com

turbocharging systems for passenger cars

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