1. technology and computing

BorgWarner ignition coil technology
More ignition energy
Less consumption
Ignition coil technology
Sparkling ideas for
the engines of tomorrow
Compact plug top coils
Pencil coils
How do you master the technological challenges of
developing highly charged engines? How do you exploit
the potential for reducing fuel consumption and exhaust
emissions without making compromises in the vehicle‘s
dynamic performance? How do you optimize your
costs and optimize the quality at the same time? As
one of the worldwide leading providers of advanced
ignition technology, BorgWarner gives important
answers to these questions. Our experience with ignition technology goes back over 100 years and for over
40 years we have developed the most modern ignition
2
coils. So it is no coincidence that almost all carmakers
worldwide rely on innovations from BorgWarner.
One important idea with which the vehicle industry is
increasingly preparing for future exhaust standards is
the downsizing of internal combustion engines. Apart
from turbocharging, exhaust gas recirculation and lean
combustion processes, it is especially the ignition system which is an important component in optimizing the
process of combustion. Engines with reduced swept
volume differ significantly from classical, naturally
Multi spark ignition systems
Dual coil ignition systems
Ecoflash high frequency ignition systems
aspirated engines. On the one hand, space in the
engine compartment is generally tighter, on the other
hand modern, low swept volume engines work with
high compression ratios and turbocharging. This
means that pressures in the combustion chamber
increase and with that the requirements and loads on
the ignition system. While for naturally aspirated engines, an ignition voltage of between 20,000 to 30,000
volts is enough to ignite the fuel-air mixture, the latest
generation of highly charged engines need the latest
generation of ignition voltages of up to 40,000 volts.
With innovative developments such as the compact
plug top coils, multi spark ignition coils, the dual coil
ignition system or the high frequency Ecoflash ignition,
we provide the definitive support to the car industry to
master the challenges of engine development.
3
Ignition coil technology
Compact plug top coils.
More ignition energy for modern engines.
Space-saving, high performance, long-lived. These are the characteristics which distinguish
the innovative compact plug top coils from BorgWarner. This latest generation of ignition
coils was developed especially for the tight spaces available in the latest down-sized
petrol engines and ensures the correct ignition voltage and higher ignition energy.
The compact plug top coil with a spring-loaded
connection: This allows the use of spark plugs
with a lengthened insulating neck for an increased
breakdown voltage.
All of the benefits at a glance
• Higher ignition voltage and ignition energy
• Especially compact, weight-saving design
• High breakdown voltage via spring-loaded connection
• Modular design for optimal modifications to customer requirements
4
Compact ignition power
The new compact plug top ignition coils from
BorgWarner have a permanent magnet and an
optimized magnetic circuit. This means that, corresponding to customer requirements, an especially
space-saving geometry can be combined with
improved ignition performance. Although the new
ignition coils are more compact than conventional
coils, they generate higher ignition energy and a
higher ignition voltage. This enables optimal combustion of the fuel, thus leading to lower emissions,
better fuel efficiency and higher performance. In
addition, new plastics and an innovative, extremely
reliable connection technology for the components
inside the body of the ignition coil ensure a decisive
increase in the reliability and in the service life of the
plug top coil.
High breakdown voltage
Another special feature of the new ignition coils is
their high breakdown voltage. At higher ignition voltages, unwanted flashovers can occur, which take the
common SAE connection to its physical limits. This
problem can be effectively counteracted with an
optimized design of the ignition coils and the spark
plugs. BorgWarner thus offers a plug top ignition
coil with a spring-loaded connection for use at the
highest ignition voltages. It permits the use of spark
plugs with an insulating neck which has been extended by up to 8.5 mm and an innovative „bowl“ connection through which the required minimum breakdown voltage is easy to achieve, thus guaranteeing
reliable ignition of the fuel-air mixture.
Tailor-made ignition coils
The new compact plug top ignition coils‘ numerous
positive aspects include their modular construction.
The new ignition coils consist of a base component
and variable, customer-specific items, such as the
fixing mechanism, the housing as well as the connector and its connecting angle. Vehicle makers can
thus make use of ignition coil technology which is
reliable, which has been tested many times, and
which can be quickly tailored to the engine concerned. In the same way, the electronics to control the
ignition coil can be integrated into the housing of the
ignition coil or into the engine control unit – depending on the type of vehicle and on the customer‘s
requirements.
The benefits of modular construction: The base components of the new compact plug top ignition coils can be
combined with variable, customer-specific parts.
5
Ignition coil technology
The multi spark ignition coil.
So that sparks really fly.
One important development based on the ignition
coil technology from BorgWarner is the multi spark
ignition coil.
So far a conventional single spark coil has been
sufficient to supply a spark plug with a spark
suitable to start ignition. With more and more
powerful engines, with high exhaust gas
recirculation rates, with turbocharging and
stratified charge operation, a single spark
is coming to its limits. One focus of our
development work has thus been to
increase the frequency and variability
of the ignition spark produced by the
ignition system.
The principle of the multi spark ignition
coil is based on the repeated supply
of energy: After the first spark between the spark plug‘s electrodes,
the ignition coil is recharged during
the ignition cycle and, in subsequent
discharges can supply additional
ignition energy at short intervals
of time, thus extending the total
duration of the spark. Within a
millisecond, up to four sparks
can be triggered like this,
within a combustion cycle.
When used in new ignition
systems, our multi spark
ignition coil thus makes
an important contribution
to further improve fuel
consumption and exhaust emissions as well
as smoothness running.
Multi sparks ignite better: After the first spark,
the multi spark ignition coil is recharged and
can immediately supply more ignition energy.
All of the benefits at a glance
• Increased variability and frequency of ignition sparks
• Extension of the total spark duration
• Optimisation of fuel consumption, emissions and smoothness running
6
BorgWarner dual coil ignition system.
Dual coils ignite longer.
engine‘s requirements. In comparison to conventional
ignition coils, the new dual coil technology from
BorgWarner offers significantly shorter ignition delays
and more stable combustion over the entire range of
engine speeds, particularly in the partial load zone.
Owing to its flexibility, the dual coil ignition system is
especially well suited for use in modern engine designs
with very lean combustion and large quantities of recirculated exhaust gases, which make a particularly high
performance ignition system necessary.
Charge
Coil 2
The dual coil ignition system represents another innovation in ignition technology with two magnetic coils in
one housing. In comparison to conventional ignition
coils, using two coils per spark plug enables significantly shorter ignition intervals as well as more precise
timing of the ignition at differing engine speeds and
with quick charge changes. The integrated electronic
control also permits continuous charging and discharging of the magnetic coils, which makes it possible to
exactly control the ignition voltage and ignition energy
required in each case, depending on the engine load,
and minimizing the fuel consumption. The ignition system thus offers the option of extending a single uninterrupted ignition spark over a long period, opening up the
possibility of varying the ignition energy to match the
Coil 1
Discharge
Charge
Discharge
Spark duration
The dual coil ignition system:
For shorter ignition intervals and
a very long, uninterrupted single
ignition spark.
Time (ms)
Ignition
Extended spark duration
Spark current
Dual coil ignition
Conventional ignition
All of the benefits at a glance
• Shorter ignition intervals
• More precise timing of the ignition at differing engine speeds
• Reduction of fuel consumption by exact control of the ignition voltage and energy
• Shorter ignition delays and more stable combustion
7
Ignition coil technology
The high frequency Ecoflash ignition.
A revolution in ignition technology.
To further increase the efficiency of internal combustion engines, new combustion processes
are needed which in turn need new ignition systems. With the design of the Ecoflash high
frequency ignition, BorgWarner is currently developing a solution, which sets new standards
in the optimization of fuel consumption, of emissions and of how engines run.
Technological challenges
Downsizing of petrol engines brings about high levels
of turbocharging, and the resulting pressure increase
leads to significant increases in the ignition voltage
required. Tight limits are however set on this development by the limited dielectric strength of the
available insulating materials. A reduction of the ignition voltage at high pressures is thus an important
requirement on future ignition systems. On the other
hand, if the charge is to be diluted by exhaust gas
recirculation or if lean mixtures are used to lower the
fuel consumption, the reduced flammability of the
mixture becomes a limiting factor. This makes higher
ignition energies necessary to prevent misfiring.
Stratified charge designs require either the duration
of the ignition to be extended or the activated volume
to be increased to ensure stable inflammation in every
combustion cycle. With homogeneous combustion
processes using high charge dilution, the latter alternative - enlarging the ignition volume - has the
advantage of providing a much more precise ignition
timing and accelerating the slowed down combustion, thus making it more effective.
The idea of the system
In contrast to conventional systems, which start
combustion with a spark, the high frequency ignition
EcoFlash creates a spatially extended high-energy
corona discharge in the combustion chamber. Under
these conditions even extremely lean fuel mixtures
are reliably ignited, and using novel combustion processes such as HCCI in large-scale applications
becomes feasible. In addition, the working principle
All of the benefits at a glance
• Enormous potential savings in fuel consumption, CO2 and nitrogen oxide emissions
• Reliable ignition of extremely lean fuel mixtures
• Suitable for alternative combustion processes such as HCCI or stratified charging designs
• Exact monitoring of the combustion process is possible
8
of EcoFlash - voltage transformation by means of a
high frequency resonant circuit under closed-loop
control - opens up several new ways of performing
combustion diagnoses.
Ignition technology for potential savings
The potential savings from the new BorgWarner
ignition technology are enormous, as independent
testers have already confirmed. Petrol consumption
and CO2 emissions can be reduced by up to
10 percent, nitrogen oxide emissions can even
be reduced by about 40 percent. And all of this is
possible with the engine running up to 15 percent
more smoothly. Thanks to intensive work by our
development engineers and a system with manageable complexity, our Ecoflash technology will be
ready for production in good time before the European CO2 directive becomes effective.
The high frequency Ecoflash ignition creates an extended
corona discharge which reliably ignites even extremely
lean fuel mixtures.
9
Ignition coil technology
The classic BorgWarner ignition coils.
As various as our customers‘ vehicles.
BorgWarner‘s classic ignition coil range is characterized by its variety as well as by its
high reliability and cost-effectiveness. Very precise ignition components are used, which
can optionally be supplemented with integrated ignition electronics with additional safety
and diagnostic functions. Tailor made developments for customers and optimal systems
integration ensure that the engine concerned will be perfectly matched.
Distributor ignition coils
For ignition coils with an ignition distributor, the high
voltage produced by the coil is fed to the distributor.
The distributor then distributes this high voltage to the
corresponding spark plugs.
Block ignition coils
In a block ignition coil, several ignition coils are collected
together and control several spark plugs via ignition
leads. There are block ignition coils with or without an
integrated end stage and in single or dual spark versions.
All of the benefits at a glance
• Temperature range up to 150 °C
• Ignition voltage over 30 kV
• Long service life and high reliability due to use of high quality materials
• Ideal ratio of weight to performance
10
Ignition coil rails
Several individual ignition coils are collected together
into one ignition coil rail. This is then pushed directly
onto the spark plugs. For early detection of false firing,
knocking and misfires, the coils can also be equipped
with an integrated ion current measurement system,
to monitor the optimum combustion of the mixture.
Plug shaft/plug top ignition coils
Plug shaft/plug top ignition coils (single or dual spark)
are pushed directly onto the spark plugs. This means
that the ignition energy can be transferred directly to
the spark plugs, practically without any cable losses.
Another advantage: The existing plug shaft, depending
on its shape, can be used to install the ignition coil.
Plug shaft and plug top ignition coils are used in
vehicles with fully electronic ignition.
11
Ignition coil technology
Innovation
Implementation
We offer leading technologies. From design through to
Intensive research and a permanent dialogue with
leading research centers and universities have ensured
BorgWarner`‘s technological leadership for decades.
However, there are other important factors which make
us the development partner for car makers around the
world.
Apart from recognizing the future requirements of the
market early on and having comprehensive know-how
about engines these include innovative production
processes and high degree of vertical integration in
manufacturing. We are thus able to quickly convert
12
innovative product ideas into tailor-made solutions and
to manufacture in high quality right from the start of
production.
Working in a close partnership with our customers, our
engineers develop trailblazing solutions which exactly
match the requirements concerned in each case.
We offer all of the services that you need from a single
source: from CAD development, FEA calculations and
simulation in parallel to development, the choice and
pairing of materials as well as electronics, via testing
series production.
electromagnetic compatibility (EMC), process failure
mode and effects analysis and high performance
manufacture of samples (A, B and C samples) through
to 100 percent testing on our own test benches.
Before a part is released for production, it goes through
extensive test runs and quality checks. On the most
modern systems and with the latest processes we
record all of the important physical and chemical
parameters thus guaranteeing the high functionality
and long service life, for which BorgWarner products
are renowned worldwide. Also for series production
we leave nothing to chance. Trailblazing, in part patented production processes and very modern, fully
automated production lines for ignition coils at production facilities in America, Europe and Asia ensure
the uncompromising quality of BorgWarner ignition
coils.
Being the single source for the series manufacture
also puts us in the position of being able to guarantee
a reliable supply of ignition coils to our customers.
13
Ignition coil technology
Working closely together
High reliability
14
You don‘t become the market
leader by chance. But by first
class quality.
On the streets of the world, the ignition technology from BorgWarner
shows day for day how it works with outstanding reliability, even under
the most extreme conditions. The exceptional reliability and long service life of our products are guaranteed by the high quality standards
to which we develop, test and produce our products around the world.
Even our suppliers are chosen according to strict criteria. We only
work together with the best suppliers who are certified to meet our
quality standards and who guarantee a reliable supply of the required
raw materials and parts. We proactively ensure their ability to deliver
with help from the Advanced Delivery Performance Monitor. This is a
unique analysis tool for the automatic detection of supply risks, for
which we have already been awarded several prizes, amongst others
with the „Supply Chain Innovation Award“ 2012 and the „VDA Logistics
Award“ 2013.
We ourselves work with quality which is certified worldwide: Our plants
are certified to DIN ISO 9001, which acknowledges our highest quality
standards in design, function and performance as well as the constant
optimization of our products and services. Apart from that our plants
have been awarded certificates for QS 9000, VDA 6.1 and ISO TS
16949 as well as the environmental certificate ISO 14001.
Our staff also demonstrate first class quality in our customer service. This
begins with support from our highly qualified engineers and continues
through to our excellent delivery service. Via a closely meshed sales
network we ensure that our products are at the right place at the right
time. And that everywhere on the planet.
15
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
BorgWarner Ludwigsburg GmbH
Mörikestraße 155
71636 Ludwigsburg, Germany
Phone +49 7141 132-0
Fax +49 7141 132-350
BorgWarner Ningbo
No. 188, Jingu Zhong Rd. (West)
315104 Yinzhou District, Ningbo, China
Phone +86 574 8820 9088
Fax +86 574 8810 1145
BorgWarner Ludwigsburg GmbH
Plant Muggendorf
Am Bahnhof 3
91346 Wiesenttal, Germany
Phone +49 9196 100
Fax +49 9196 596
BorgWarner Chungju Ltd.
248-69, Samchong-Ri, Judok-Eup
Chungju-City
Chungchongbuk-Do 380-882, South Korea
Phone +82 43 852 9946
BorgWarner - Ramos Arizpe
Blvd. Kappa #1125
Parque Industrial Santa Maria
25903 Ramos Arizpe, Coahuila, Mexico
Phone +52 844 866 0200
Fax +52 844 866 0245
BorgWarner Emissions Systems
Dixon
1350 Franklin Grove Rd.
Dixon, IL 61021
Phone +1 815 2881462
BorgWarner Piracicaba Ltd.
Av. Comendador Leopoldo Dedini, 310
13422-210 Piracicaba, Brazil
Phone +55 1934299000
BorgWarner Tralee Ltd.
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
BorgWarner Esslingen GmbH
Hindenburgstraße 146
73730 Esslingen, Germany
Phone +49 711 3152-0
Fax +49 711 3152-210
BorgWarner Esslingen GmbH
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 1.11.13 | Bestell-Nr. 5 040 000 024
* Joint Venture
emissions.borgwarner.com