Borg Warner, one of the world’s leading Tier 1 suppliers for drivetrains and transmission systems, has a vast and diverse product range. This includes transfer cases, all-wheel-drive couplings, electronic limited slip differentials, torque vectoring axles and hybrid/electrical vehicle drive systems to mention but a few. Its customers include several global automotive OEMs and it has, so far, has provided over 8.4 million active all-wheel-drive systems and over 5.5 million ECUs by 2011.
In early July, BorgWarner announced the sale of its spark plug business to Federal-Mogul. The sale includes manufacturing facilities in Chazelles, France and Neuhaus, Germany. The completion of the transaction is subject to regulatory approvals. The spark plug business was a small segment of the BERU operations that BorgWarner acquired in 2005. Sales were about $80 million in 2011. BorgWarner will continue its focus on expanding the core BERU Systems products of glow plugs, diesel cold start systems and other gasoline (petrol) ignition technologies.
In India, BorgWarner’s drivetrain systems do duty in several Mahindra and Tata passenger vehicles. The Mahindra XUV500 features the company’s NexTrac 120 FWD system while the Land Rover Freelander is equipped with the Haldex Gen IV FWD unit. The company’s RWD systems are seen on the Scorpio, Scorpio Getaway, Tata Xenon pickup and Tata Safari, while its Torque-On-Demand RWD system does duty on the Tata Aria.
The company is also working with Maruti Suzuki to develop automatic transmission technology for small cars. Such a development has major implications given that small cars not only account for a huge share of the carmaker’s business but also account for an overwhelming share in the Indian auto sector.
However, the challenge is to introduce the product at an affordable price given the cost-sensitivity of the market. It has, therefore, been considering either a joint venture or a wholly-owned subsidiary in India to manufacture the critical components for the automatic transmission (AT) when developed, if volumes justify it. The small dual-clutch technology (DCT) for the automatic transmission could well find its way to the small car market in Japan and China.
Earlier this year, Borg Warner had taken took a group of Indian journalists to its Kweeenaw Research Center at Houghton in Northern Michigan to demonstrate several drivetrain technologies. Here is a quick snapshot of the technology revealed.
NexTrac on-demand AWD system
This system incorporates an electro-mechanical actuated primary clutch. This, says BorgWarner, is a simple and refined design approach as compared to the conventional technique. The primary clutch’s friction material consists of an organic material which improves clutch-life and has a better performance in the NVH department. This system has a compact design and is manufactured with lightweight materials that enhance fuel economy. This system’s design consists of an integral coil and connector which easier assembly and is very robust for warranty.
Currently used on the Hyundai Santa Fe SUV, the coupling system is fitted between the rear differential and the propeller shaft and engages. The rear differential is engaged by this system and hence power is transmitted to the rear wheels when needed. The SUV remains a front-wheel-drive vehicle in normal driving conditions. This vehicle works jointly with the stability control system of the car. It cuts power automatically if the vehicle starts losing grip.
Haldex Gen V On-Demand AWD
This is a patented Centrifugal Electro-Hydraulic actuator system (CEH) that cuts cost by 25 percentand weight by 28 percent. The CEH Actuator eliminates the need for an accumulator, solenoid control valve and filter that translates into the cost reduction. In terms of weight, the reduction is 1.8kg.
By using this actuator, this system engages the coupling’s internal clutch hydraulically. Torque accuracy and response performance are achieved without a pressure sensor. As it has fewer parts, costs have been contained. This system will feature on the 2013 Volkswagen Tiguan SUV.
FWD/AWD disconnect drive
This system features a high-efficient 2WD mode for improve fuel economy. It has a side-mounted on-demand AWD coupling and also features Borg Warner’s patented CEH actuator. It is also equipped with an automatic oil sump level control system and a staged clutch pack clearance mechanism that help in low drag. This system also features an electro-mechanical power transfer unit (PTU) disconnect. It is also equipped with integrated AWD coupling and PTU controls.
In Drive-Disconnect controls
BorgWarner’s systems have three switch modes:
2WD/AWD mode: In this mode, the vehicle will be able to stay in 4WD mode when needed regardless of all other driver or vehicle inputs.
Auto Mode: In this mode, the vehicle will switch between the 2WD and AWD depending upon driving and environmental conditions. It activates by sensing the inputs from factors such as ambient temperature, windshield wipers, driving surface friction co-efficient and hill detection. The auto mode also keeps track of driving variables such as an aggressive launch (high throttle and clutch slip), any unintended clutch clip, excessive lateral or longitudinal acceleration, aggressive steering manoeuvres, or abnormal ABS events. The driving conditions are combined to create a map that defines and tells the system when to enter or exit AWD mode. This system was demonstrated on a modified Cadillac SRX crossover.
Torque Vectoring AWD: This system features a through-the-road hybrid drive with 20 percent improved fuel economy over conventional FWD system. It comprises a secondary electric drive axle that eliminates the PTU and prop shaft. The torque vectoring system helps in enhanced vehicle handling and stability.
Two-speed On-demand AWD
This system, as the name suggests, is an on-demand system which can be switched on or off whenever needed. It features an enhanced response, controllability and NVH. It consists of an electromagnetic clutch actuation system and works via a two-speed shift technology. An estimated 4.5 million units are already doing duty in many countries. This system is currently on the RWD Ram 1500 Pickup with a 5.7-litre Hemi engine.
eAWD system
This system can be paired with any FWD vehicle where Haldex installs an electric motor on the rear axle. This system is capable of giving the car the same AWD characteristics. It uses that electric motor to power the rear wheels when required. This system can also be used as a full-electric system at low speeds. BorgWarner claims it can improve fuel economy by 20 percent and is currently testing it in a Saab 9-3 Wagon.