Future-proof Technologies

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Future-proof technologies
BorgWarner offers numerous drivetrain technologies for improved handling andvehicle dynamics to meet current and future demand for drivability-enhancing technologies.
By John Barlage, Director of Product Strategy, BorgWarner PowerDrive Systems

Introduction

Due to recent trends, all-wheel drive (AWD)
and advanced drivetrain solutions which
provide enhanced drivability enjoy great
popularity. With its complete line of transfer
cases, AWD couplings, electronic limitedslip differentials, torque vectoring technology and hybrid/electric vehicle driveline
systems, BorgWarner has the right technology for virtually any circumstances, ascan be seen in Figure 1 .

Figure 1 . While improving fuel economy by up to25 percent compared with a mechanical AWD
system, BorgWarner’s eAWD system provides increased vehicle stability and dynamics.

The success story of BorgWarner
PowerDrive Systems

The story of BorgWarner’s PowerDrive division commences in the early 20th century
BorgWarner Knowledge Library 201 6in Muncie, Indiana, where Tom and Harry
Warner designed a differential gear for automobile transmissions which allowed avehicle’s two drive wheels to turn at different speeds during cornering. Being established in 1 901 , the Warner Gear Company
had great success with the first standardtransmission for all makes of cars in 1 91 9.
The Borg-Warner Corporation was foundedin 1 928 by merging Warner Gear withBorg & Beck and two other companies.
Twelve years later, BorgWarner’s Warner
Gear division expanded its portfolio by adding innovative transfer cases. While customer expectations with regard to highquality and outstanding performance havenever changed, the technologies themselves have advanced considerably.

Growing popularity of AWD systems
Since 1 990 in particular, the automotive industry has witnessed tremendous growth in
the demand for vehicles with AWD systems. Besides the established markets ofNorth America, Western Europe, Japanand South Korea, the main drivers of thisgrowth are the so-called BRIC countries
Brazil, Russia, India and China. All-wheel
drive applications, originally reserved for1

Figure 2. Compared with previous technologies, BorgWarner’s well-proven GenV AWD coupling
features a light and compact design for reduced vehicle complexity and easier integration into thedrivetrain.

sport utility vehicles (SUVs) because of
their advantages off the road, are now ingreat demand across all vehicle segments.
In particular, drivers value the improved
handling, dynamics and stability resulting
from these technologies.

AWD solutions for enhanced safety

The dominant AWD architecture continues
to be active on-demand AWD, in which one
axle is the primary driven axle and torqueis transferred to the secondary axle whenneeded. In this context, BorgWarner offersthe GenV electronically controlled AWD
coupling, a well-proven technology which
automatically distributes power between
the front and rear wheels, see Figure 2. To
accomplish this, a new lightweight andcompact design for reduced vehicle complexity and easier integration into the drivetrain is used. BorgWarner’s AWD couplingdelivers an immediate pre-emptive response with a high torque accuracy. Calculation is carried out by the integrated elecBorgWarner Knowledge Library 201 6

tronic control unit based on data provided
by the on-board electronics. If required,full locking torque is available at any timeand any speed, depending on road conditions and vehicle load distribution.
This widely respected all-wheel drive coupling was the first major product launch after
BorgWarner acquired the Swedish-based
Traction Systems division of Haldex AB in2011 . Originally patented by Sigvard Johansson in 1 998, it was based on a unique differential pump that created a hydraulic flow
proportional to the difference in velocity overthe coupling. Using a linear throttle valvethat was activated by a stepper motor, thestiffness could be varied and the torquetransfer controlled.

FXD – Electronic limited-slip differential system for FWD vehicles

Another future-oriented technology from
BorgWarner PowerDrive Systems is theindustry-first electronic limited-slip diffe2

Figure 3. Controlling the locking torque between the front wheels and directing power to the wheel withthe best traction, BorgWarner’s industry-first electronic limited-slip differential system for FWD vehicles
offers enhanced stability.

rential system for vehicles with front-wheel
drive (FWD), commonly known as front
cross differential (FXD), which is being
displayed in Figure 3. Launched in theVolkswagen Golf GTI with Performance
Pack, the system constantly communicateswith on-board electronics as well as vehicle
sensors, using data such as steering angle,
engine torque or yaw rate to adapt thetorque to practically all possible driving situations. FXD prevents wheel slip before
it occurs by controlling the locking torquebetween the front wheels and directing
power to the wheel with the best traction.
During cornering, it delivers a torque vectoring effect to prevent understeering. To
reduce oversteering, FXD provides a yawdamping effect. The result in both cases isenhanced vehicle stability.

nization function in conjunction with a powertransfer unit (PTU) provides mechanicaldisconnection for improved fuel economy.
It features the rationally designed Centrifugal Electro-Hydraulic (CEH) actuator. With
its long-established competencies resulting
from over a hundred years of experience,
BorgWarner PowerDrive Systems is able
to offer a large product portfolio which canmeet the constantly growing demand forenhanced driveline solutions. Following
current major trends such as all-wheel
drive and driveline disconnect technologies; GenV, FXD, eAWD and the Disconnect Coupling provide a fun-to-drive, highly
efficient experience across all vehicle segments and under practically all driving conditions.

Future-proof product portfolio

Contact

Finally, BorgWarner’s disconnect couplingallows the secondary axle to be disconnected from the driveline, and a synchroBorgWarner Knowledge Library 201 6

Email: technology@borgwarner.com
For more information please visit
borgwarner.com
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