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Newsline Pierburg GmbH’s Emission Control business unit powerfully positioned worldwide A talented specialist in emission reduction Neuss. For almost 18 months now, Pierburg’s former Emission Control product group has been operating as an autonomous profit-center style business unit. With altogether four locations outside of Germany in Lanciano, Italy, Ústí nad Labem, Czech Republic, Abadiano, Spain, and Fountain Inn, USA, as well as three German plants in Neuss, Berlin and Hartha, this unit is a globally successful specialist in all aspects of automotive emission reduction, specifically nitrogen oxides (NOx) and hydrocarbons (HC). Pierburg’s emission-reduction systems, particularly the various exhaust gas recirculation (EGR) valve options, are nowadays employed by nigh all the international carmakers. sman Sari, Senior Manager Development for EGR (automobiles), explains the available product range: “Our lineup comprises solutions for both sparkand compression-ignition engines, for automobiles and trucks. In all these instances, the EGR valve in all its manifold options is our star product. Irrespective of whether pneumatic, electric or motor actuated, with or without bypass, with or without the new cooler unit, over six million valves are sold annually to the international automotive OEMs, representing indisputable proof of their star quality. We are in a position to offer our customers precisely what they need, from rugged, generalpurpose solutions to components em- bodying maximum controllability and dynamic response. Those customers combining our EGR valves with other Pierburg options such as the aluminum cooler or the exhaust-gas flaps for regulating pressure differences, achieve further marked reductions in nitrogen oxide emissions.“ Javier Egurrola, Head of the Emission Control unit, adds: “Besides the recirculation of exhaust gas, the use of secondary air systems is another proven option for lowering gasoline engine emissions. Injecting air into the exhaust gas manifold results in an exothermal oxidation of the hydrocarbons still remaining in the exhaust gas which, in turn, leads to a significant reduction in these emissions and also in carbon monoxides. A spin-off: the heat released by this reaction assists the downstream catalytic converter in reaching more readily its operating temperature, essential in achieving further emission reductions. Here, too, we have the suitable systems.“ Dr. Holger Paffrath, Senior Manager Development for Secondary Air Systems, explains: “Besides our standard classic comprising a low-noise secondary air pump shielded against spray and dust by a welded plastic housing and driven by an encapsulated D.C. motor, we have since 2003 also been offering a larger, low-noise secondary air pump able to feed sufficient secondary air to both high capacity gasoline engines and vehicles 12 with engine compartments having limited installation space. Either pump can be mounted to the engine or the body of the car. For the latter option we also supply a modular assembly kit comprising a clamp and absorbers to eliminate structure-borne noise.“ Paffrath goes on: “To avoid an exhaust gas backflow into the secondary air pump or its immediate environment as well as any uncontrolled influx of air into the exhaust system outside of secondary-air operation, we are also offering three different types of secondary air valve: firstly, an on/off check valve (remarkable for its low pressure-losses); secondly, our vacuum-independent secondary air valve that opens automatically, depending on the pressure generated by the secondary air pump and can therefore dispense with an electric actuator and all the vacuum hose lines and, thirdly, our electric secondary air valve that combines the advantages of the check valve with those of the secondary air valve while offering the added benefits of rapid opening/closing times and ample opening force. This electric secondary air valve can also been fitted with an integrated pressure sensor to address future requirements regarding onboard diagnosis (OBD II) and electronic on-board diagnosis (EOBD).“ The third product group comprises the already-mentioned exhaust-gas flaps. These flaps are not only used to reduce emissions, they also enhance vehicle drivability. Dr. Karl-Heinrich Talented specialists in emission reduction: Javier Egurrola (r.) and Osman Sari seen here with a motor-actuated EGR valve. Lösing, Senior Manager Development for EGR valves (trucks) and for exhaustgas flaps, comments: “In the case of emission control, these flaps can be combined with DeNOx catalytic converters, in other words converters for abating nitrogen oxide emissions. By (Continued on page 13) Photo: Markus J. Ferger
egulating the exhaust gas inflow, depending on temperature, the flap ensures that the converter is more or less always working to optimum efficiency, a factor that also extends its servicelife considerably.” “Another example,” continues the 58year-old exhaust gas specialist “is to ensure compliance with future EURO 5 standards which specifically in the case of diesel engines increasingly call for low-pressure EGR for achieving an especially high rate of recirculation. There is also the sequential turbocharger feature, of growing significance on diesel engines, where an additional smaller turbocharger ensures that the power boost available is delivered even at low engine speeds. Last but not least, noise control on upscale vehicles is a factor for consideration;various sound profiles are selectable, from a muffled to a throaty sports car style roar.” “Neither should we forget,” adds Lösing, “the EGR valves for commercial vehicles that work at temperatures of up to 180° C under punishing conditions of aggressive exhaust condensate and pressure surges as steep as 1,300 bar/sec. These valves are necessary to ensure that trucks and buses, too, can comply with current and future emission standards.” Javier Egurrola continues: “What really distinguishes us from competition is the know-how and experience of our employees accumulated through more than 30 years of market presence, and enabling us nowadays to mix and merge a diversity of components (e.g. EGR valve with bypass or the new cooler), thus creating new, innovative and nonetheless rugged products matching the highest standards of quality and customer demands. Our entire team as well as their profound knowledge re- Newsline Pierburg GmbH’s Emission Control business unit powerfully positioned worldwide A specialist in emission reduction (Continued from page 12) garding our products and present and future emission control techniques and, not least of all, the expectations and needs of our customers—these are the key factors that set us apart from competition.” As to the future, the Emission Control business unit perceives itself as strategically well positioned. Egurrola: “The advantage of having an autonomous profit-center style business unit is that, unlike previously, it assumes full responsibility for such factors as design, timing, profit and quality throughout a product’s lifecycle. Secondly, the business unit is focused on a specific product sector and can leave the development of tomorrow’s products to the Advanced Engineering department. This, Powerfully positioned product portfolio: Dr. Karl-Heinrich Lösing (l.) Senior Manager Development EGR (trucks) and Exhaust-Gas Flaps and his Secondary Air Systems coworker, Dr. Holger Paffrath, with the latest high-temperature exhaust gas flap. in turn, results in a more efficient division of labor. And, finally, a structure such as this functions according to a global vision that starts with group guidelines and is reflected in the global coordination and meshing of activities within the various departments and branches with a view to achieving a common goal. All this gives us the energy to confidently cope with future developments and actively help shape the future of the automobile.” Pierburg expert Lösing has a quite specific notion of how this future will shape out. “We can be certain that in future the entire area of engineering development and simulation will play a 13 much more predominant role in the relationship between the carmakers and their suppliers. Also likely to undergo considerable change are the requirements regarding flexibility in terms of engineering design changes and the perception of the engine and the auto as complete systems in themselves.” Adds Sari, his engineering colleague: “In future, our customers will require even more than today technical support in the design and test phases. They will also expect us to park on their premises one of our application engineers for direct consultation.” A glance at the list of projects currently in the pipeline indicates that the Emission Control business unit is focusing its product range closely on futurerequirements and emission standards. Alongside a new generation of EGR valves, we find such undertakings as EGR valves for commercial vehicles or for exceptionally high flow rates, others with an integrated bypass function or else for low-pressure operation. A further item on the agenda is an optimized sec- Photo: Markus J. Ferger ondary air system. Javier Egurrola concludes: “The new business unit set-up is a sustainable system to help us achieve present and future performance targets. Since its conception we have attained over 30 percent added productivity through the resulting changeover in process layout and materials flow. Moreover, through improved First Time Quality (FTQ) we have managed to upgrade our Overall Equipment Efficiency (OEE), in some cases by over 50 percent. Measured against our business plan we have also shown a 17-percent sales boost. From such a promising baseline we are certain of having laid for ourselves a sound foundation and hence look forward to solid business progress in the years ahead.”
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