BorgWarner introduces onboard battery charger

BorgWarner introduced its Onboard Battery Charger (OBC), adding to the company’s impressive portfolio of technologies for plug-in hybrid and pure-electric vehicles. This technology uses silicon carbide technology and is best-in-class for power density, power conversion efficiency and safety compliance, the company says.

The OBC is installed in hybrid or electric vehicles to convert alternating current (AC) from the power grid to direct current (DC) for charging batteries.

This technology accepts an extended range of AC inputs including 7.4 kilowatt (kW), 11 kW and 22 kW power ratings with DC-to-DC converter rating integration from 2.3 kW to 3.6 kW as an option. It is compatible with all battery chemistries and voltages of 400 volts, 650 volts and 800 volts.

BorgWarner OBCs have a wide range of charging powers and capabilities. The OBC with a rated charging power of 7.4 kW can also be used for charging powers of 1.8 kW, 3.3 kW and 6.6 kW and uses a single-phase supply from the power grid.

The OBC with a rated charging power of 11 kW is more efficient with its three-phase grid supply and fast charging strategy, while the onboard charger rated at 22 kW is even more efficient with its three-phase supply and therefore much faster charging.

2012 Subaru Impreza with 30% fuel economy improvement uses BorgWarner variable cam timing technology

BorgWarner’s Cam Torque Actuated (CTA) variable cam timing (VCT) technology with new mid-position lock system helps improve fuel economy for the 2012 Subaru Impreza. According to Subaru, the 2012 Impreza offers 30% better fuel economy compared with the previous model year.

The 2012 Impreza is powered by a new four-cylinder 1.6-liter Boxer engine (available in Japan only) and 2.0-liter Boxer engine (available globally) which meet US Super Ultra Low Emissions Vehicle (SULEV) and Euro 5 emissions standards.

BorgWarner’s patented CTA technology takes advantage of the existing torsional energy in the valve train to phase the camshaft, similar to a hydraulic ratchet. Compared with traditional oil pressure actuated cam phasers, CTA cam phasers operate more quickly and under a wider range of engine speeds and temperatures, enabling engines to run more efficiently at all engine speeds with faster response. BorgWarner received a 2009 Automotive News PACE Award for this technology.

BorgWarner’s latest advancement in CTA technology is the new mid-position lock system, named a finalist for a 2011 PACE Award. Because conventional systems default to one end of the camshaft phaser’s range of angular travel, calibration strategies are limited by the restricted amount of travel that can be designed into a variably timed system.

BorgWarner’s mid-position lock technology defaults at an intermediate position to allow for a greater range of travel and more control over airflow for improved fuel economy, function and efficiency. A patented hydraulic circuit passively moves the system to the mid position for reliable repositioning in nearly any potential engine operating condition with no added active relocking control.

UQM Technologies in Conjunction With BorgWarner Team Up To Manufacture Electric Powertrains

The CODA Sedan With UQM Electric Drivetrain

UQM Technologies is collaborating with BorgWarner on electric powertrain products for all-electric and hybrid-electric passenger automobiles.

Initially, the companies are working together to integrate UQM Technologies’ PowerPhase electric propulsion system with BorgWarner’s 31-03 eGearDrive transmission for the all-electric CODA front-wheel drive five-passenger sedan, scheduled for introduction in the California market in mid-2010.

The UQM PowerPhase electric propulsion system has a peak power rating of 100 kW (134 hp) and a continuous power rating of 45 kW (60 hp). It delivers peak torque of 300 N·m (221 lb-ft) and continuous torque of 160 N·m (118 lb-ft).

With a diameter of only 280 mm (11 inches) and a weight of 46 kg (102 lbs), this motor will fit easily in a wide range of passenger vehicles, including subcompacts. The system also features optimized four-quadrant performance, dynamic torque, speed and voltage control, and system energy efficiency of more than 90% across a substantial portion of its power curve.

The BorgWarner 31-03 eGearDrive transmission is suited for mid-range electric vehicles on either front-wheel drive or rear-wheel drive transverse driveline applications. An eGearDrive system is featured on the Tesla Roadster electric vehicle.

The single-speed 31-03 uses a unique flange and coupling for adaptation to the PowerPhase motor housing to accommodate input shaft speeds of up to 14,000 rpm with a wide range of reduction ratios and very high operating efficiency. The 31-03 is also available with an optional ePark feature, an electronically actuated park lock system.

An electric powertrain consisting of a UQM PowerPhase electric propulsion system mated with the BorgWarner 31-03 eGearDrive transmission provides a compact and torque-dense package, delivering nearly 2,000 N·m (1,500 lb-ft) of torque with a gear ratio of approximately 6.5 to 1. The package will propel a mid-size passenger vehicle at highway speeds with economical, high powertrain efficiency.

Source: Green Car Congress