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Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
BorgWarner BERU Systems Engineers Ireland 10/12/2013
CONFIDENTIAL INFORMATION
2
Introduction and Purpose of the Conference
Introduction
• William O’Connor Engineering Manager
Purpose
• Brief Introduction of BorgWarner BERU Tralee
• Introduction of the BorgWarner BERU Tralee Products
• Discussion on Engineering Skills Requirements
CONFIDENTIAL INFORMATION
3 3 3
BorgWarner BERU Systems History
1912 1929 1978 1986 2000 2001 2007 2010
Spark-plug factory
founded
by Julius Behr and
Albert Ruprecht
Development of
the first glow plug
First dual-coil self
regulated glow plug
(Preheating time:
5-7 sec. World Wide
Patented
First international production
plant in Tralee, Ireland.
Followed by more national and
International BERU locations.
BERU Electronics
GmbH founded
in Bretten
Product
innovation:
electronically
controlled
diesel instant
start system
Opening of the
extended research
and development
center (RDC) in
Ludwigsburg
BERU-Eichenauer:
joint venture for
PTC auxiliary
heating systems
Acquisition of
BERU Eichenauer
Joint Venture
(PTC Heaters)
BERU becomes
a BorgWarner
Unit
CONFIDENTIAL INFORMATION
4
2012 Sales: $7.18 Billion ($8.05B unconsolidated)
Employees: 19,100
Operations: 57 Locations
19 Countries
Products: Engine, Transmission and Driveline systems
Market Drivers: Fuel Economy
Emissions
Performance
BorgWarner at a Glance
Financial and Employee
information as of
December 31, 2012
Location information as of
December 31, 2012
CONFIDENTIAL INFORMATION
5 5
Engine Drivetrain
Americas 20 Locations
Europe 18 Locations
Asia 19 Locations
Strategic Global Operations
57 Locations in 19 Countries
Location information as of December 31, 2012
CONFIDENTIAL INFORMATION
6
Global R&D
Asia Europe North America
CONFIDENTIAL INFORMATION
7 7
Engine 68% / SALES Drivetrain 32% / SALES
Turbo Systems • Wastegate
• Variable Turbine Geometry
(VTG)
• Regulated 2-stage
(R2S™)
Thermal Systems
• Thermal Management
Components and Systems
• Visctronic® Systems
• Fans/Fan Drives
Emissions Systems
• Exhaust Gas Recirculation
(EGR) Valves
• EGR Coolers & EGR tubes
• Integrated EGR Modules
• Secondary Air Systems
• Actuators
Morse TEC
• Engine Valve Timing Systems
-Timing Chain
• Variable Cam Timing
- Oil Pressure Actuated
-Torsional Assist
- Cam Torque Actuated
• HY-VO® Transmission Chain
- Transmission/Transfer case
chain
BERU Systems
• Glow Plugs
• Instant Start System
• Pressure Sensor Glow Plugs
• Gasoline Ignition Technology
• Sensor Technology
• PTC Cabin Heaters
Thermal Systems
Emissions Systems
Turbo Systems
Morse TEC
BERU Systems
Transmission Systems
TorqTransfer Systems
• AWD Couplings
• Transfer Cases
• Electronic LSD and Torque
Vectoring Systems
• HEV and Electric Drive
Systems
• AWD Electronic Controls
and Systems Integration
Transmission Systems
• DualTronic® Systems for Dual
Clutch Transmissions
• Transmission Control Modules
and Solenoids
• High Pressure Transmission
Control and Actuation Systems
• One-way Clutches
• Friction Plates
TorqTransfer Systems
A Portfolio of Leading Automotive Technology
CONFIDENTIAL INFORMATION
8
BorgWarner BERU Systems supplies Original Equipment, to OEM’s, Tier I’s as well as into the Aftermarket
Diesel Cold Start
Technology
Ignition Technology
Electronic and
Sensorics
BW BERU Systems – Main Products
Pressure Sensor
Glow Plug
Vapourizer
Ignition Coil
Plug Top
High Temperature
Sensor Cabin Heater
Self Regluating
Glow Plug
Glow Plug / Heating
Control Module
Instant Start Glow
Plug
Intake Air
Heater (IAH)
High Frequency
Ignition Ignition Coil
Pencil
Dual Coil
Ignition
CONFIDENTIAL INFORMATION
9
Cabin Heater Application
Product Description:
The cabin heater heats up the cold air after engine cold start in winter time.
It is located in the Heating-, Ventilation, and Air-Conditioning-Unit (HVAC),
just behind the coolant heat exchanger.
Gen I
(Electronic)
Gen II
(Mechanical)
Gen III
(Mechanical
& Electronic
Product:
Cabin Heater based on PTC (Positive Temperature Coefficient) Technology
CONFIDENTIAL INFORMATION
10
BorgWarner BERU Cabin Heater Product Portfolio
Low Voltage for Vehicles with ICE (Internal Combustion Engine, 12V - 62V)
High Voltage Heaters for Electric- & Hybrid Vehicles ( up to 450 V)
Standard
Mechanical Cabin Heater
500W - 1kW
Gen I:
fin design
Gen II:
extruded profile design
Compact
Mechanical Cabin
Heater
100W – 400W
Air 5 kW Liquid 5,5 kW
Standard
Electronic Heater
1kW – 2kW
Gen I design,
Interfaces:
PWM, LIN & CAN
Standard
Electronic Heater
1kW – 1.2kW
Gen III design,
Interfaces:
PWM, LIN & CAN
CONFIDENTIAL INFORMATION
11 11
BorgWarner PTC Cabin Heater Customer Overview
Product Brand Vehicle HVAC Supplier Electronic
B9 Yes (400V)
MQB
C7 (A6-4F)
PQ35
No
No
No
C1 MCA
C1
Y55x
Yes
Yes
Yes
X250 Yes
X61B No
Airscarf SL No
P356, P473 Yes
Cursor & V No
CONFIDENTIAL INFORMATION
13
BorgWarner BERU: High-Voltage PTC Cabin Heater (Air)
Product Description:
the HV PTC Heater for air replaces the coolant heat
exchanger and is the only heat source for passenger
comfort in the car
Technical Overview:
• electrical power from 3 kW up to 5 kW @ 200 V – 400 V
• software controlled power regulation
• developed according HV standards, tested with 2000 V
• galvanic isolation between high voltage side (power)
• and low voltage side (control)
• connection to all kind of vehicle interface networks:
• PWM, LIN-Bus and CAN-Bus
Benefits:
• closed loop software controlled
• homogeneous temperature profile
• no power degradation over lifetime
• diagnostic capability
• self regulated max. temperature due to PTC effect
Coolant heat exchanger HV PTC Heater Air replaced
CONFIDENTIAL INFORMATION
BorgWarner HV Air PTC Heaters
Gen 2 3 KW 4 kW Demo
BMW E-Mini
Demonstration Vehicles
2008 IAA Frankfurt 2011 since 2012
4 kW Series
BRABUS EV 4WD
Demonstration Fleet In Field
PSA Partner (above) & Berlingo
CONFIDENTIAL INFORMATION
15
Engineering Skills
• Materials & Applied Physics – Barium titanate (PTC), Platinum rhodium (Sensors)
• Mechanical Engineering – Concept proposal, 3D Modeling, Thermal and Stress Analysis
• Electronic Engineering – Embedded Hardware and Software development
• Product Testing and Validation – Design and Process Validation
• Quality Engineers – ISO/TS 16949 – Quality Walk, DFMEA, QFD
• Manufacturing and Production Engineering
• Program Management
CONFIDENTIAL INFORMATION
16
Non Technical Skills
• Communication – internal and external
• Financial Understanding – DCF for each RFQ
• Design <->Manufacturing relationship
• Team player – ability to work within a team
• Common Sense !
CONFIDENTIAL INFORMATION
17
Thank You
better fuel economy
reduced emissions
great performance