Post on 07-Apr-2018
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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