1. technology and computing

BorgWarner Diesel Cold-Start Technology
Lower emissions
Greater efficiency
Diesel Cold-Start Technology
Brilliant ideas for
tomorrow‘s engines
Instant Start Systems
Steel Glow Plugs
How do optimize the comfort and reliability of diesel
cold starts? How do you minimize consumption and
exhaust emissions of diesel engines while improving
their running performance and responsiveness? How
do you secure your technological lead – while maintaining maximum quality? As the world‘s leading
provider of advanced diesel cold-start technology,
BorgWarner offers answers to these important questions.
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For more than 100 years we have been developing
ignition systems and diesel cold-start technologies,
and today we are still a key player in the present and
future of engine development with numerous
innovations.
It is no coincidence that all over the world motor
vehicle makers turn to innovative products from
BorgWarner. Especially in the growing market for
Pressure-Sensor Glow Plugs
Ceramic Glow Plugs
diesel engines we are clear leaders with our technologies.
Because with innovative developments such as the
Instant Start System ISS, the Pressure Sensor Glow
Plug PSG or the glow plug with ceramic heating element,
we significantly reduce fuel consumption and emission
values. We continue to make major contributions and
support the automotive industry to master tomorrow‘s
challenges.
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Diesel Cold-Start Technology
The BorgWarner Instant Start System ISS.
Starting without delay.
Today‘s car buyers have ever increasing expectations in relation to driving comfort. This
includes a rapid engine start without a delay. BorgWarner engineers have made a gasoline
engine like key start possible for diesel vehicles. The key is the Instant Start System ISS.
The system concept
The BorgWarner ISS consists of an
electronic glow plug control unit and
performance-optimized glow plugs
with a reduced heat-up time of at
most 2 seconds – compared to
5 seconds for a standard glow plug.
Both in the heat-up and in the
steady-state phase, our ISS glow
plugs require significantly less energy.
Power semi-conductors are used in
the control unit as switches to control
the glow plugs, replacing the electromechanical relays used in the past.
Compared to the conventional selfregulating glow plugs, the coil combination of the power-optimized glow
plug of the ISS is much shorter and
the glow zone is reduced to around
one third. In direct-injection engines,
this corresponds to the part of the
heating rod that projects into the
combustion chamber.
Control unit and glow plugs of the electronically
controlled ISS glow plug system.
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Electronic control
The 2nd generation ISS
When the engine is running, the glow plug is cooled
by charging cycles and air movement in the compression phase. The temperature of the glow plug
will go down with increased speed at a constant
glow plug voltage and injection quantity, and will
increase with an increasing injection quantity at
constant glow plug voltage and speed. The electronic control unit can compensate for these effects:
the glow plugs are always supplied with the optimum effective voltage for the respective operating
point. The glow plug temperature can thus be controlled according to the operating state. Furthermore,
the combination of the low-voltage glow plug and
the electronic control unit is used to heat up the
glow plug extremely quickly. This is done by applying the full on-board voltage to the glow plug for a
pre-defined period, and only then firing with the
necessary effective voltage in synchronized operation.
The normal pre-heating time is thus reduced to a
maximum of 2 seconds even at low temperatures.
The efficiency of the system is so high that hardly
more voltage is drawn from the on-board power
supply than is actually required by the glow plug.
As each glow plug can be controlled by a separate
power semiconductor in the ISS, the current in each
glow current circuit can be monitored separately.
This makes individual diagnostics for each plug
possible.
In consistent refinement of the ISS technology we are
providing the automotive industry with the 2nd generation of ISS with integrated intake air pre-heating. The
control unit controls the glow plug quick-start function,
and also optimally actuates the heater flange in coordination with the engine control unit. Unlike the glow
plug, which creates the purely local ignition conditions
for the air-fuel mixture, a heater flange increases the
temperature of the air flowing into the cylinder, thus
creating optimized overall conditions for fuel ignition.
The ISS 2 with control unit and additional heater flange
make a further reduction of consumption and fuel emissions possible.
Technical features
• Gasoline engine like key start down to –15°C
(at –25°C only 2 seconds pre-heating)
• Controllable temperature for pre-, intermediate
and post-heating
• Simple and flexible application
• OBD-compatible, operation of all common interfaces
• Independent of engine and control unit
• Wide range of applications due to high degree of
flexibility of glow plugs
• Increases electrical load on the engine for
improved support of diesel particle filter
regeneration in the low load range.
The glow plug of the
ISS System optimized
for direct injection
(right) converts the
input power in the
head area more
efficiently and needs
only around half as
much as energy as
a conventional glow
plug (left).
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Diesel Cold-Start Technology
The BorgWarner Pressure Sensor Glow Plug PSG.
Intelligent technology for lower emissions.
New emission laws in Europe, Asia and in the USA will further reduce the permissible exhaust gas emissions of diesel engines. The thresholds for NOx and particulate emissions,
which are relevant for the diesel engine, will in future be up to 50 % lower than the current
values. These emission standards will be difficult to meet with conventional solutions alone.
With the advanced Pressure Sensor Glow Plug PSG, we support engine developers in
meeting these challenges.
Glow plug body
Gasket
Glow plug
heating rod
High-current
connection
Measuring membrane
Circuit board with electronics
The glow plug as an intelligent pressure sensor
With modern particulate filter systems, the required
reduction in particulate emissions seems to be
achievable. However, the presently available exhaust
treatment measures alone will not suffice to fulfill the
NOx targets. Considerable improvements will also
be required in the engine‘s raw emissions. Intensive
research is therefore being conducted in alternative
combustion processes, such as HCCI (Homogeneous
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Charge Compression Ignition), HCLI (Homogeneous
Charge Late Injection), HPLI (Highly Premixed Late
Injection) and DCCS (Dilution Controlled Combustion
System), which all produce very low NOx emissions.
Many of our customers are also vigorously driving
forward the development of alternative combustion
processes. The new process requires a very high
degree of precision in metering injection quantity,
injection point and exhaust gas recirculation rates
All advantages at a glance
• Measurement of cylinder pressure up to 200 bar with a precision of +/–2 % and a resolution of up to 700 steps per combustion cycle
• Continuous adjustment of fuel injection, charging pressure and exhaust gas recirculation rates by the engine control unit
• Cylinder-specific optimization of ignition
• Operation of the engine in the optimum window between maximum performance and minimum exhaust gases
• Reduction of combustion noises
• Long-term stability of the combustion process
• Effective compensation of injector ageing
• Improvement of cold-start and cold running qualities
• Optimum control of the torque
• Compensation of component tolerances, inaccuracies in the fuel measurement, various operating conditions and fuel qualities (like wide variation of cetane numbers e.g. in the USA)
• Reducing the need for exhaust aftertreatment
in alternative combustion processes, which in turn
requires constant monitoring of the combustion process. This demands a sensor – a role which the
glow plug located in the combustion chamber can
assume.
The development engineers at BorgWarner have
developed an intelligent solution and integrated a
piezo-resistant pressure sensor in the plug. In view
of the extremely high temperatures, vibrations and
pressure conditions in the cylinder head, the mechanical design of the glow plug is a critical factor. The
heating rod is not as was the case pressed into the
glow plug body, but is stored as an elastically moving
part. And it transmits the pressure to a membrane at
the rear of the glow plug.
The actual pressure sensor is thus positioned away
from the combustion chamber in a zone with significantly more favorable ambient conditions. Thermal
load on the seal remains controllable as a heating
rod of the Diesel quick-start system ISS is used,
which only glows at its tip.
electronics. These precise and long term stable
pressure signals make it possible to comply with the
ever stricter exhaust gas limits – by building a
closed-loop control. This means that new extended
functionalities, that were previously not available, can
now be supported: combustion control, cylinder
balancing, peak pressure control, compensation of
varying fuel qualities, long-term stability, cold-start
improvement, NVH/acoustics optimization and
diagnosis.
Technical features
• Piezo-resistive pressure sensor
• Movable heating rod for pressure transmission
• Robust sealing element between body and heating rod
• Miniaturized electronics integrated in top of the glow plug
• Calibrated and programmed as per Advanced Functionality
customer specifications
• Integrated concentric automotive plug
The Pressure Sensor Glow Plug PSG measures the
pressure in the combustion chamber via the integrated sensor and relays it to the engine control
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Diesel Cold-Start Technology
The BorgWarner Ceramic Glow Plug.
Fast, heat-resistant, long lasting.
The high requirements in terms of refinement, low emissions and performance made on modern
diesel engines usually results in poorer starting characteristics. A problem that is exacerbated
by low compression diesel engines. Beside glow plugs with an efficient cold-start function,
modern engine designers are also looking for solutions, that make heat energy available when
the engine would otherwise generate higher emissions due to excessive cooling.
The forwad looking ceramic glow plugs from BorgWarner fulfill these requirements – from rapid
temperature rise to a high maximum temperature. At the same time they are characterized
by high-durability and long life.
Design of the ceramic heating rod of the BorgWarner ceramic glow plug
Glow pin contact
External conductor
Insulator
Internal conductor
Cap area
Insulator
External conductor
Heating zone cap
The heating element consists entirely of electrically
conductive ceramic. Because its surface has a higher
specific resistance than the material of the supply and
return conductors, the glow rod only glows at the tip
(cap) and thus reaches high temperatures more rapidly.
The glow pin contact consists of an internal and external
conductor separated by an insulator.
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Shorter heat-up times
The key advantage: the BorgWarner ceramic glow
plug heats up much quicker than conventional ceramic glow plugs. Their heating element is inside the
glow pin, which must first be heated up completly.
In the following production stages, the ceramic glow
pins are first released and then compressed by gas
pressure sintering. Because of the unique composition
of our ceramics, this process is conducted in a special
furnace in a protective gas atmosphere under high
pressure. The ceramic pins then become electrically
conductive and mechanically stable enough to be
given their final form in a technically challenging grinding
process. Finally the electrical contacts to the ceramic
are established with the metallic components innerpole
and protective sleeve and the ceramic pin is installed.
Technical features
• Glow temperature up to 1,300°C
• Extremely rapid heat-up time in under 3 seconds to 1,300°C
• Extended life time
• Optimized close-loop control for pre-, intermediate and post-heating
• Exact measurement of the glow plug resistance
• Innovative production process
Innovative production
The superior properties of our solutions compared
with conventional ceramic glow plugs are due to an
innovative production process.
The ceramic heating rod is shaped in a co-extrusion
process. Conductors are thereby processed to create
a ceramic „cable“ and cut into suitable lengths. The
actual heating material is attached to the tip of the
glow pin as a kind of cap in a spray injection process.
Co-extrusion sections are sawn out of an endless
co-extrudate bead.
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Diesel Cold-Start Technology
The BorgWarner Steel Glow Plug.
Protecting both environment and engine.
Current diesel car engines are equipped with 3-phase glow technology (pre-heating,
start-heating, post-heating). This means that the glow plug not only glows before and
during the start-up phase, but also for 180 seconds after the start. That protects the
environment and conserves the engine.
The afterglowing BorgWarner GN glow plug only needs
2 to 5 seconds glow time during a cold-start.
How a 3-phase glow plug works
The electronically controlled pre-heating starts
when the ignition lock starter switch is operated and
lasts for 2 to 5 seconds at normal ambient temperatures until the engine is ready for start. The postheating time is up to 3 minutes after starting the
engine to minimize pollutant and noise emissions.
The engine operating state is determined, for
example, by measurement of the coolant temperature. The post-heating process is continued until the
coolant has reached a temperature of 70°C, or it will
be switched off after a certain time set in the
characteristics map. If the coolant temperature is
higher than 70°C before the start, no post-heating
will take place
Protection against overheating
Self-regulating rod glow plugs limit the current flowing from the battery to the plug with increasing tem-
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perature to prevent overheating. However, when the
engine is running, the voltage will increase to a point
at which glow plugs that are not designed for 3-phase
glow technology will burn out.
Furthermore, the plugs that are supplied with current
are exposed to high combustion temperatures after
the start, and are thus heated up from the inside
and the outside. The afterglowing BorgWarner rod
glow plugs are operational at full generator voltage.
Their temperature increases very quickly, but will
then be limited by the regulating coil to a steadystate temperature that is lower than that of non-post
heating plugs.
Rapid start
With the afterglowing GN glow plug, it has been
possible to reduce the glow time to 2-7 seconds.
To achieve this, the designers reduced the diameter
of the front end of the heating rod. The heating rod
thus starts to glow very quickly in this zone. At a
temperature of 0°C, this takes just 2 seconds until
start. At even lower temperatures, the system is
adjusts to the requirements by the glow time control,
and increases the glow time as needed: at -5°C
approx. 5 seconds and at -10°C approx. 7 seconds.
Reduction of white and blue smoke
White or blue smoke is emitted from the exhaust
until the ideal ignition temperature has been reached.
These kinds of smoke are the result of incomplete
combustion of the fuel as a result of a too low ignition
temperature. Post-heating of the GN glow plug
causes the diesel fuel to burn more completely and
with less noise during the warm-up phase. Smoke
opacity is thus reduced by up to 40 %.
Good-bye to cold-start knocking
Knocking during a cold-start of a diesel engine is
caused by an increased ignition delay when the
engine is cold. The fuel ignites abruptly, the engine
knocks. Pre-heating and post-heating of GN glow
plugs ensure that the engine reaches the operating
temperature more quickly. This preserves the engine,
results in a quieter engine running and prevents
knocking. The fuel will then be burnt more evenly
and more completely. More energy is thus released
and the combustion chamber temperature will increase quicker.
Three-phase
alternator
Switching principle of a post-heating glow
system with four quick-heating rod glow
plugs connected in parallel and temperature
sensor.
Battery
Ignition lock
starter switch
Starter
Electronic
control unit
Indicator lamp
Technical features
• Quick-start glow plug in slim line design
• Short preheating time of approx. 2 to 7 seconds
T °C
1050
850
• Reliable start (even at -30 °C)
• 40 % less pollutant emission during the warm-up phase
• Start is gentle on the engine
• Improved quiet running of engine, knock-free
• For vehicles with operating voltages up to 14.5 V
t
Pre-heating Start heating Post-heating
2 – 7 secs approx. 2 secs approx. 180 secs
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Diesel Cold-Start Technology
We offer leading technologies.
From design to series production.
Intensive research and ongoing dialog with leading research centers
and universities have ensured the technological leadership of BorgWarner for decades. However, there are other important factors that
make us the development partner of choice for car makers all over
the world. In addition to a correct sense for the future requirements
of markets and comprehensive automotive engineering know-how,
these are innovative production procedures and real production
depth. We are thus in a position to convert product ideas into customer-specific solutions and to manufacture at a high quality right
from the start.
In close partnership with the customer, our engineers develop pioneering solutions that are precisely tailored to the respective requirements. We offer our comprehensive range of services on a onestop basis: from the development by means of Catia V5, material
selection and material pairing and electronics, through inspection of
the electromagnetic compatibility (EMC), failure modes and effects
analysis (FMEA), efficient sample constructions (A, B, and C samples) to 100 % testing on our own test rigs and for EMC specification.
Before a component goes into series production, it is put through
comprehensive test procedures and quality checks. In state-of-theart production plants and with the latest procedures, we factor in all
key physical and chemical parameters and thus ensure a high level
of functionality and durability for which BorgWarner products are
known worldwide.
Nor do we leave series production to chance. Cutting edge, in some
cases patented production processes and state-of-the-art, fully automated glow plug manufacture at our production facilities underwrite
the uncompromising quality of BorgWarner glow plugs.
Series production from a single source likewise enables us to supply
our customers with glow plugs flexibly and reliably.
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On the two-axis cold roller in the BorgWarner production
and development center, ignition systems, glow plugs, diesel
instant-start systems (ISS) as well as sensors and electronic
components are tested under driving conditions.
Innovation
Implementation
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Diesel Cold-Start Technology
Close cooperation
High reliability
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You don‘t get to be the market
leader by chance. But with top
quality.
Day in, day out on roads all over the world, diesel cold-start technology from BorgWarner proves its outstanding functional reliability –
even under extreme conditions. The above average reliability and
durability of our products are guaranteed by the high quality standards according to which we develop, test and produce our diesel
cold-start technology worldwide.
Even the suppliers are selected according to strict criteria.
BorgWarner works exclusively together with top suppliers that are
proven to meet our quality standards and can assure us of reliable
delivery with the required raw materials and parts.
We ourselves are working with certified quality worldwide:
All our plants are certified according to DIN ISO 9001 which attests
highest quality standards regarding form, function and performance
and a permanent optimization of product and service. The German
plants are also certified according to QS 9000, VDA 6.1 and ISO TS
16949 and the environmental standard ISO 14001.
Our staff in our customer service department also exhibit first class
quality in customer service. This starts with support by highly qualified engineers through to the outstanding delivery service: with our
dense sales network we ensure that our products get to the right
place at the right time. Anywhere in the world.
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BorgWarner Emissions Systems
America
Europe
Asia
BorgWarner Inc.
BorgWarner Powertrain Technical Center
3800 Automation Ave
Suite 100
Auburn Hills, MI 48326-1782, USA
Phone +1 248 754 0112
Fax +1 248 754 9572
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Mörikestraße 155
71636 Ludwigsburg, Germany
Phone +49 7141 132-0
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No. 188, Jingu Zhong Rd. (West)
315104 Yinzhou District, Ningbo, China
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BorgWarner Ludwigsburg GmbH
Plant Muggendorf
Am Bahnhof 3
91346 Wiesenttal, Germany
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BorgWarner Chungju Ltd.
248-69, Samchong-Ri, Judok-Eup
Chungju-City
Chungchongbuk-Do 380-882, South Korea
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Blvd. Kappa #1125
Parque Industrial Santa Maria
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Phone +52 844 866 0200
Fax +52 844 866 0245
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Dixon
1350 Franklin Grove Rd.
Dixon, IL 61021
Phone +1 815 2881462
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Av. Comendador Leopoldo Dedini, 310
13422-210 Piracicaba, Brazil
Phone +55 1934299000
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Monavalley Industrial Estate
Tralee, County Kerry, Ireland
Phone +353 66 7125111
Fax +353 66 7125883
BorgWarner Emissions Systems
Unipessoal Lda.
Parque Empresarial de Lanheses, Lote 1
Lugar de Salvaterra
4925-432 Lanheses, Portugal
Phone +351 258 249 000
BorgWarner Emissions Systems Spain S.L.
Ctra. Zamáns, 20
36315 Vigo, Spain
Phone +34 986468302
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Hindenburgstraße 146
73730 Esslingen, Germany
Phone +49 711 3152-0
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Plant Oberboihingen
Gustav-Wahler-Straße 1
72644 Oberboihingen, Germany
Phone +49 7022 6004-0
Fax +49 7022 6004-730
BorgWarner (Thailand) Ltd.
700/153 Moo 1,
AMATA Nakorn Indutrial
T. Bankao, A. Panthong
20160 Chonburi, Thailand
Phone +6638 210196-20
Beru Diesel Start Systems Pvt. Ltd.*
Navlakh Umbre, Tal. Maval,
Plot No. A-13/2, Opp. General Motors,
Talegaon MIDC
Poona 410507, India
Phone +91 2114 306789/799
Fax +91 2114 306779
BorgWarner Emissions Systems
(Sales Office)
Sumitomo Fudousan,
Shin-Yokohama Bldg 10F
222-0033, Yokohama
Kanagawa prefecture, Japan
Phone +81 4547006807
BorgWarner Emissions Systems India Pvt. Ltd.
Plot No-19,Sec-5,IMT Manesar
Haryana-122050, India
Phone +91 124 455 6300
Fax +91 124 455 6399
Printed in Germany · 3.07.12 · Bestell-Nr. 5 100 001 072
* Joint Venture
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