BorgWarner has developed a new EGR valve for diesel engines that promises to lower emissions and improve durability Tightening emission norms is driving manufacturers and suppliers in search of new technologies. With the sale of new generation diesel on the rise and a greater focus on deriving better emission control in diesel engines auto makers are asking for better and more innovative solutions from their suppliers. Although diesels have lower carbon dioxide emissions than gasoline engines, they have the potential to emit more smog-causing nitrogen oxides (NOx) and particulates. Ask Roger Wood, President and General Manager, BorgWarner Turbo & Emissions Systems, and he quickly answers, "As emissions regulations continue to tighten in many countries, car manufacturers are demanding EGR solutions that will fit within a limited space in the engine compartment". BorgWarner has developed a new diesel exhaust gas re-circulation (EGR) valve for lower emission and higher product performance. The EGR valve uses BorgWarner's patented technology, featuring higher force, lower cost, improved durability, flexible packaging and smaller size. "Building on our EGR system expertise, BorgWarner has developed innovative technologies to help diesel car manufacturers meet present and future NOx regulations while offering more flexible packaging and smaller size", adds Wood. Effectively limiting NOx formation by lowering the peak combustion temperature in the engine, the new diesel EGR valve features a DC motor actuator combined with a unique drive system to provide fast response within a smaller package. Robust, patented anti-contamination features, including effective seals and stem scraper, improve durability. Suitable for many packaging configurations, the DEGR valve can be used in both hot-side and cold-side applications, as well as in single or dual poppet systems. It can also be easily combined with an EGR cooler and cooler bypass valve.Wood expresses, "As the market for fuel efficient diesel vehicles continues to expand, we expect an increase in demand for existing and new EGR products". "BorgWarner will continue to develop innovative solutions to meet and exceed ever stricter emissions regulations", he summarises. The diesel EGR valve, which satisfies Euro V standards, is currently produced in Germany and will be manufactured in China as well. In 2009, several engine programs will be launched with a major OEM.Working towards cutting fuel consumption and further enhancing the efficiency of diesel engines, BorgWarner's technological prowess is also evident from the new two-stage turbocharging and variable turbine geometry (VTG) technologies that are emerging on the market. Capable of meeting the most stringent requirements in respect of power development and environmental compatibility, these technologies are claimed to be instrumental in the present day diesel engines having 30 per cent lower fuel consumption than gasoline engines and around 25 per cent less CO2 emissions. According to sources at BorgWarner, the new developments in turbocharging technology are enabling the diesel engines to comply with current and future Emission Standards (Euro 5 and Euro 6, besides US07 Bin5). The new diesel engines featured in the Volkswagen Tiguan demonstrate this potential. VW's new Tiguan is the world's first mass-produced car with a highly turbocharged engine. Two four-cylinder diesel engines with common-rail injection have output of 140hp and 170hp and courtesy the intelligent turbocharging systems from BorgWarner Turbo & Emissions Systems, both power plants already comply with the Euro 5 Emission standard that will come into force from 2009.The new turbocharging technology has made turbochargers more productive yet smaller and lighter. This has also triggered engines with less displacement and less cylinders that ensure lower frictional losses and better engine efficiency. For example, the compact K04 twin-scroll turbocharger with integrated thrust circulating air valve ensures harmonious power development in the 2.0-litre power plant of the new Vauxhall GT (Opel GT in Germany). The Peugoet 207RC is another vehicle to contain the K03 turbocharger with twin-scroll technology. With a displacement of 1.6-litre, the 207RC' engine develops a torque of up to 260Nm. Since manifold and turbine casing are combined in one component made of highly creep-resistant material, the benefits afforded also include thermodynamic advantages and less installation space. As a result, the engine features a harmonious, strong power development with smooth operation over the entire engine-speed range. The Audi 1.8 TFSI and the VW 1.4 l engine also incorporate the K03 turbocharger with integral manifold.The new Porsche 911 Turbo is also boosted with two BV50 G turbochargers from BorgWarner Turbo & Emissions Systems. This marks the first time that this technology that has, to date, been reserved for the domain of the diesel engine, has been used in a mass-produced gasoline engine. BorgWarner has developed the VTG guide vanes made of highly creep-resistant materials, some of which are spin-offs from the aerospace industry, in order to meet the stringent requirements in respect of exhaust gas temperatures. The variable turbine geometry ensures that the entire exhaust gas stream passes the turbine wheel and can be used immediately again for increasing power. This substantially enhances response in the lower engine-speed range.