A-BorgWarner
Business
Press Information
Contact
Hans-Peter Vater
+49(0)7141 132 233
PI_305
Reference 6,890
Innovative sensor solutions for power train and exhaust system
For almost 30 years BERU has been providing its partners in the
automobile industry with high-performance and individual sensor systems
from a single source.
Ludwigsburg, May 26, 2009 - Modern cars and commercial vehicles are more intelligent than
ever before. In the power train and exhaust system alone there are up to 30 sensors performing
a very wide variety of functions: They take measurements, convert the results into electric signals,
supply the information needed for control and regulating functions to the control units handling modern
engine-management, safety and comfort systems. “Increasingly demanding exhaust gas limits and
constantly rising safety and accident prevention requirements mean that sensors take on an increasingly important role,” explained Dipl. Ing. Ulrich Schneider, Sensors Product Manager at
BERU’s head office in Ludwigsburg. “The tolerances within which, for example, the fuel consumption and exhaust gas utilization processes must take place optimally, producing the lowest possible
emissions, are becoming ever tighter. This is why in this field it is not possible to imagine being
without sensors as monitoring devices”.
With its current range of products BERU has specialized increasingly in innovative sensor solutions for the power train and exhaust system. In this field, the specialist in Ignition Technology, Diesel Cold-Start Technology, Electronics and Sensors, based in Ludwigsburg, is able
- 1 of 5 -
to offer a wide variety of customized sensor-based measurements. These include the following
products:

Temperature sensors such as the new BERU high temperature sensor (HTS) for applications in Diesel particle filters, oxidation catalytic converters, SCR systems, NO x storage cats and turbo chargers,

Movement sensors such as speed sensors, distance and angle sensors,

SMART sensors with intelligent electronics such as the radiator identification sensor
(RIS), developed by BERU.
Sensor measurements customized to requirements
With the new HTS sensor BERU has developed an accurate, fast temperature sensor, offering stability, and structural versatility. The aim was to develop a closed sensor, which, among
other things, would meet the demands for short response times. Further development aims included:

a measuring range of minus 40 to plus 950 degrees Celsius,

a standard characteristic line as per DIN IEC 751,

plug and play capability,

extremely long service life,

high resistance to exhaust gas by careful materials selection and with special design,

flexible fitting position,

flexible dimensions and geometry to meet customer requirements,

an “one size fits all solution” for the greatest possible flexibility in production and manufacturing technology.
The HTS sensor element, made of platinum with standardized characteristic line and
OBD capacity in temperature ranges from below 50 to 950 degrees Celsius, is the best possible
combination of measurement range, signal yield and stability. The HTS is a closed high temper- 2 of 5 -
ature sensor, the structure of which is based on very many elements from BERU’s glow plug
design.
Its construction offers many advantages, such as a short response time. In addition such sensors can be installed into almost any fitting position. Another advantage is that while with open
sensors there is always the risk that the tip will collect carbon deposits, this form of clogging
does not occur with closed structures. The HTS is also extremely flexible when it comes to fitting: Depending on customer requirements, it is possible to achieve immersion depths of 25 to
70 millimeters as well as bending angles of 90 to 180 degrees.
The latest BERU developments in its range of movement-measuring sensors include a
distance sensor for Fiat’s 1.3 liter Diesel engine with turbo charger. The sensor is based on a
magneto-static principle. It measures the position of the pneumatic actuators, which are responsible in a turbocharger for adjusting the turbine blades to enable the boost pressure to be variably
regulated.
Most distance, angle, and speed sensors from BERU are based on the Hall-IC principle
of measurement. This type of measurement technology is relatively low-cost and is also easily
adjusted to individual customer requirements. To this end it is possible to program the distance
sensors. Working in close cooperation with its partners in the automotive industry, the developers are currently working on what are known as “through the wall” sensors. These can measure
distances without making direct contact, for example the distance between a magneto attached
to a swirl flap in front of the intake valve and the angle sensor.
The intelligent smart sensors segment also includes the radiator identification sensor
(RIS). In North America a form of vehicle-specific emissions trading can be conducted for vehicle radiators with a coated radiator network for active air cleaning. This special radiator coating
converts ground-level ozone into oxygen. This is contingent on the existence and perfect operation of the radiator in the vehicle at all times. The RIS guarantees this. It generates an error
message if a non-catalytic coated radiator is installed, and tells to the driver to go to the nearest
workshop. Audi, BMW and Mercedes-Benz are already using the RIS sensor in series production.
- 3 of 5 -
Sensors and software expertise from a single source
BERU develops highly specialized smart sensors such as the RIS and other sensor systems to
suit special customer requirements. In addition the company also provides its development
partners within the international automotive industry with comprehensive services from a single
source. Automotive suppliers benefit from more than 30 years of experience in the sensor sector and from tremendous manufacturing expertise in the fields of metal processing and plastics
engineering. The sensor solutions are developed and produced at the headquarters in Ludwigsburg and also at BERU Electronics in Tralee, Ireland. The required sensor technology software is created at BERU Electronics in Bretten.
BERU is meeting increased customer demands for an expansion of the testing facilities
of new products - necessary from the point of view of quality - and at the same time reducing
development times, at its Research and Development Centre (R&D) in Ludwigsburg and at the
EMC production facility, where sensor applications can be tested for their electro-magnetic
compatibility in the vehicle environment.
305_1: BERU has specialized increasingly in innovative sensor solutions for the power train and
exhaust system. Within this segment the Ludwigsburg Company covers a wide variety of sensor
measurements, by providing temperature sensors, movement sensors and SMART sensors to
meet individual customer requirements.
- 4 of 5 -
BERU AG is a majority-owned subsidiary of BorgWarner Inc. based in Auburn Hills, Michigan,
USA. BERU is one of the world’s leading suppliers of Diesel Cold-Start Technology. It is also
one of Europe´s four leading suppliers in the field of ignition technology for gasoline engines.
And BERU is rapidly expanding in the electronics sector with a focus on complete electronic
systems for the automotive industry. BERU´s customers include nearly all of the world’s car and
engine manufacturers. The company is represented at 13 locations on three continents. The
Internet address for BERU is: http://www.beru.com. There you'll find more illustrations in the
BERU image database at www.beru.com/bildarchiv
BorgWarner Inc. (NYSE: BWA) is a product leader in highly engineered components and systems for vehicle powertrain applications worldwide. The FORTUNE 500 Company operates
manufacturing and technical facilities in 60 locations in 18 countries. Customers include
VW/Audi, Ford, Toyota, Renault/Nissan, General Motors, Hyundai/Kia, Daimler, Chrysler, Fiat,
BMW, Honda, John Deere, PSA, and MAN. The Internet address for BorgWarner is:
http://www.borgwarner.com
###
Statements contained in this news release may contain forward-looking statements as contemplated by the 1995 Private Securities
Litigation Reform Act that are based on management's current expectations, estimates and projections. Words such as “outlook”,
"expects," "anticipates," "intends," "plans," "believes," "estimates," variations of such words and similar expressions are intended to
identify such forward-looking statements. Forward-looking statements are subject to risks and uncertainties, many of which are difficult to predict and generally beyond our control, that could cause actual results to differ materially from those expressed, projected
or implied in or by the forward-looking statements. Such risks and uncertainties include: fluctuations in domestic or foreign vehicle
production, the continued use of outside suppliers, fluctuations in demand for vehicles containing our products, changes in general
economic conditions, and other risks detailed in our filings with the Securities and Exchange Commission, including the Risk Factors
identified in our most recently filed Annual report on Form 10-K. We do not undertake any obligation to update any forward-looking
statements.
- 5 of 5 -