Turbocharging for commercial vehicles and industrial engines
Our product portfolio for commercial vehicles includes further developments of conventional
turbochargers both with and without waste gates, turbochargers with variable turbine
geometry (VTG) and regulated multi-stage turbocharging systems (R2S), which offer
seamless coverage of the power range from 50 to 1,000 kW. As a system supplier with
a holistic approach and full scope expertise, we not only find the best solution
for every application and every market requirement, we also optimize the entire
system of the internal combustion engine through integration in modern engine management
All our turbocharging systems are characterized by excellent efficiency and broad
flow compressor wheel characteristics, by dynamic response and flexible, extremely
precise regulation. An individual application design and compact packaging ensure
optimum adjustment to the physical installation constraint of the respective engine
and vehicle. For example, we offer integrated solutions with cast-on exhaust manifolds.
Through continuous further development we constantly improve fuel consumption, performance
and emission values. The latest generation of compressor wheels and turbines ensures
optimum thermodynamic results. With the further development of materials and processing
methods – such as milled compressor wheels – we not only optimize the performance,
but also the durability and reliability of our turbocharging systems.
In addition to this, for many years our customers have enjoyed important competitive
advantages in engine development through our intensive research and major investments
in predevelopment as the worldwide technological leader. The regulated 2-stage system
(R2S), the world’s first VTG turbocharger for the off-highway segment and turbocharging
systems that enable the Tier 4, EPA 2010 or Euro6 emissions standards to be met
with zero issues are just three examples of BorgWarner’s innovative power.
It is hard to imagine modern commercial vehicle engines without some form of exhaust
gas turbocharging. After all, only with turbochargers is it possible to signifi
cantly reduce fuel consumption, meet ever stricter emissions standards and design
commercial vehicles that offer high performance while also satisfying the economic
goals of their operators.
And the potential offered by exhaust gas turbocharging is far from being fully exploited.
With innovative technologies, such as the latest generation of VTG units or the
regulated 2-stage system (R2S), BorgWarner continues to demonstrate that even today’s
refined systems offer potential for significant improvements with regard to economy,
environmental friendliness and dynamic driving performance.
Turbocharging systems for commercial diesel engines
The special requirements in the commercial vehicle sector:
- High degrees of efficiency
- Dynamic response
- Broad scope compressor wheel/turbine characteristics
- Robustness and reliability
- Highly cost effective
- Flexible, precise regulation
- Compact packaging
- Diverse concepts for exhaust gas processing
- Finely staggered range of the latest compressor wheel and turbine variants
- New B-series – developed for the requirements of future commercial vehicle engines
- New VTG BV generation in various sizes and performance classes
- Regulated 2-stage systems (R2S)
- Titanium compressor wheels
- Single flow, dual flow and water-cooled turbine casings
- Integrated waste gates and boost pressure control valves in various designs
- Turbochargers with water-cooled turbine and bearing housings, also available with
integrated boost pressure control valves
- Space-saving designs with integrated components
With our new B series and the familiar turbochargers from the K and S series, which
also employ waste gates, we offer you sophisticated and high performance turbocharging
systems for low to mid power densities. These systems seamlessly cover the entire
performance range from 50 to 600 kW per turbocharger. The broad spectrum of sizes
and types ensures that we can always find exactly the right unit to meet the most
varied of demands in the fields of commercial vehicles, construction and agricultural
machinery, industrial engines and marine engines.
The K, S and new B series turbochargers are not only particularly efficient, they
also offer a high degree of reliability, durability and the excellent quality for
which BorgWarner is renowned. In many applications that also require extreme robustness
along-side a high level of cost efficiency, our turbochargers with waste gate are
Our BV range includes pioneering turbocharging systems with variable turbine geometry
which ensure precise adjustment to the respective engine operating point. Optimum
power output with the greatest fuel efficiency is the result of this advanced technology.
BorgWarner is the only manufacturer that can offer many years of experience in the
use of VTG technology in the commercial vehicle and off-highway segment. From the
BV55, right up to the BV86, we offer a finely staggered portfolio of units that
enable optimum coordination and matching of the turbocharging system with the requirements
of our customers. Our BV series, for example, covers diesel engines with displacement
from 4 to 16 liters (244 to 976 cubic inches). A robust VTG mechanism ensures that
our BV turbo chargers operate efficiently and reliably, even under the toughest
conditions. The BV turbochargers achieve their extremely high degree of efficiency
through a CFD-optimized (Computational Fluid Dynamics) vane design in connection
with specially developed turbine wheels. Our BV turbochargers can be combined with
pneumatic actuators or with electrical actuators developed specifically for this
application. This in-house development offers massive advantages for the entire
system. For applications with severe thermal loads, we also offer water-cooled bearing
castings as an option.
Our regulated 2-stage systems (R2S) represent the pinnacle in exhaust gas turbocharging.
This high performance turbocharging system for diesel engines, which combines a
small high-pressure turbo and a larger low-pressure turbo, opens up completely new
possibilities for optimization of performance, fuel consumption and exhaust emissions
values. This is why more and more manufacturers throughout the world are now employing
this pioneering technology.
Our R2S systems allow significant increases in power density and thereby downsizing
of the engine, which in turn offers considerable reductions in fuel consumption.
At the same time, the transient response is improved even further compared to VTG.
The R2S technology allows high exhaust gas recirculation rates, even under full
load conditions, and thereby drastically reduces NOx emissions. Regulated 2-stage
systems (R2S) can also be combined with VTG technology. As pioneer of this technology,
we have comprehensive experience in the planning, design and manufacture of R2S