POWERTRAINdevelopments
efficiency. We equipped the BV55 with
BorgWarner’s new BV55 variable turbine
geometry turbocharger features a brush-
less actuator, specifically designed and
manufactured for use in heavy-duty engines
with exhaust gas recirculation valves.
TURBOS TAKE CHARGE
OF REDUCING EMISSIONS
BorgWarner next-generation turbochargers designed to fulfill
higher emissions requirements
BY ROBERTA PRANDI
B
orgWarner, a specialist in
turbocharger and emissions
technologies, has presented a
series of enhancements to its range of
turbochargers for commercial vehicle
applications.
The company offers its new B se-
ries turbochargers, along with its K
and S series, covering 75 to 1000 kW
outputs. The full portfolio is available
in a range of sizes and variations for
commercial vehicles, construction and
agricultural equipment as well as in-
dustrial and marine engines.
According to BorgWarner, its latest
generation of turbochargers, the B se-
ries, has been specified by Deutz for
installation in its newly developed 6.1
L six-cylinder diesels. The B series
provides Deutz an electrical wastegate
actuator to fulfill higher emissions re-
quirements. The turbochargers have
a milled aluminum wheel and a modi-
fied turbine housing to withstand vi-
bration loading.
Juergen Graumann, director, sales
commercial diesel Europe at Borg-
Warner Turbo Systems in Kirchheim-
bolanden, Germany, said improving
after-sales service has been a key fea-
ture in the development of the new se-
DIESEL PROGRESS INTERNATIONAL EDITION
ries and several measures have been
introduced to increase service life.
“The most significant innovation
takes a step beyond the molded alumi-
num compressor wheels to withstand
high cyclical loads, higher charging
pressures and temperatures, to remain
within the stricter emissions regula-
tions. Our engineers introduced milled
titanium compressor wheels that are
not only very hard, but also provide an
excellent strength-to-thickness ratio.”
With the titanium compressor wheel,
BorgWarner Turbo Systems is now
able to offer different compressor
wheel technologies for custom appli-
cation requirements and special cycli-
cal loads, Graumann said.
“Variable turbine geometry (VTG) is
a key technology for modern diesel en-
gines in commercial vehicles. Our new
BV55 VTG turbocharger offers optimum
low-speed engine torque characteristics
and precise control of engine boost.
“JCB for example,” Graumann said,
“equips the Ecomax T4 diesel engines
with our new BV generation.”
“Thanks to CFD (computational fluid
dynamics)-optimized vane design in
connection with specially developed
turbine wheels, the BV turbochargers
achieve an extremely high degree of
40
our new high-durability brushless actu-
ator featuring an advanced heavy-duty
geartrain to withstand the harsh duty
cycles of off-road environments. This
in-house development offers massive
advantages for the entire system.”
The new compact actuator features
12 and 24 V systems and is able to
perform in temperatures up to 140°C.
Continuous operation is available up
to 130°C, BorgWarner said.
BorgWarner offers various sizes of
turbochargers with variable turbine
geometries for diesel engines in light-,
medium- and heavy-duty commercial
vehicles. Sizes range from 3.0 to 16 L
displacements per turbocharger. This
corresponds to engine outputs of 120
to 500 kW per turbocharger.
According to Graumann, the re-
quirements in commercial vehicle
applications have shifted the industry
from using a single-stage turbocharg-
er to a two-stage device.
“At the top of our range is the regu-
lated two-stage turbocharging (R2S)
system that meets the demands of an
optimal design and allows for the con-
tinuously variable adaptation of the tur-
bine and compressor sides of the sys-
tem for each engine operating point.”
“The regulated two-stage turbocharg-
er consists of two turbochargers of dif-
ferent sizes connected in series that uti-
lize bypass regulation and can also be
combined with VTG technology.
“The R2S technology allows high
exhaust gas recirculation rates, even
under full load conditions, and thereby
drastically reduces NOx emissions,”
said Graumann.
With the importance turbochargers
play in reducing emissions, Graumann
said he expects the product in the
market for global commercial diesel
engines to rise from approximately
5.7 million units in 2011 to 7.4 million
in 2015. U
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On This Company Go To
DIRECTLINK
at www.dieselprogress.com
March-April 2011