Our Beliefs

Respect

Collaboration

Excellence

Integrity

Community

BorgWarner BERU Systems Engineers Ireland 10/12/2013

CONFIDENTIAL INFORMATION

2

Introduction and Purpose of the Conference

Introduction

• William O’Connor Engineering Manager

Purpose

• Brief Introduction of BorgWarner BERU Tralee

• Introduction of the BorgWarner BERU Tralee Products

• Discussion on Engineering Skills Requirements

CONFIDENTIAL INFORMATION

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BorgWarner BERU Systems History

1912 1929 1978 1986 2000 2001 2007 2010

Spark-plug factory

founded

by Julius Behr and

Albert Ruprecht

Development of

the first glow plug

First dual-coil self

regulated glow plug

(Preheating time:

5-7 sec. World Wide

Patented

First international production

plant in Tralee, Ireland.

Followed by more national and

International BERU locations.

BERU Electronics

GmbH founded

in Bretten

Product

innovation:

electronically

controlled

diesel instant

start system

Opening of the

extended research

and development

center (RDC) in

Ludwigsburg

BERU-Eichenauer:

joint venture for

PTC auxiliary

heating systems

Acquisition of

BERU Eichenauer

Joint Venture

(PTC Heaters)

BERU becomes

a BorgWarner

Unit

CONFIDENTIAL INFORMATION

4

2012 Sales: $7.18 Billion ($8.05B unconsolidated)

Employees: 19,100

Operations: 57 Locations

19 Countries

Products: Engine, Transmission and Driveline systems

Market Drivers: Fuel Economy

Emissions

Performance

BorgWarner at a Glance

Financial and Employee

information as of

December 31, 2012

Location information as of

December 31, 2012

CONFIDENTIAL INFORMATION

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Engine Drivetrain

Americas 20 Locations

Europe 18 Locations

Asia 19 Locations

Strategic Global Operations

57 Locations in 19 Countries

Location information as of December 31, 2012

CONFIDENTIAL INFORMATION

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Global R&D

Asia Europe North America

CONFIDENTIAL INFORMATION

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Engine 68% / SALES Drivetrain 32% / SALES

Turbo Systems • Wastegate

• Variable Turbine Geometry

(VTG)

• Regulated 2-stage

(R2S™)

Thermal Systems

• Thermal Management

Components and Systems

• Visctronic® Systems

• Fans/Fan Drives

Emissions Systems

• Exhaust Gas Recirculation

(EGR) Valves

• EGR Coolers & EGR tubes

• Integrated EGR Modules

• Secondary Air Systems

• Actuators

Morse TEC

• Engine Valve Timing Systems

-Timing Chain

• Variable Cam Timing

- Oil Pressure Actuated

-Torsional Assist

- Cam Torque Actuated

• HY-VO® Transmission Chain

- Transmission/Transfer case

chain

BERU Systems

• Glow Plugs

• Instant Start System

• Pressure Sensor Glow Plugs

• Gasoline Ignition Technology

• Sensor Technology

• PTC Cabin Heaters

Thermal Systems

Emissions Systems

Turbo Systems

Morse TEC

BERU Systems

Transmission Systems

TorqTransfer Systems

• AWD Couplings

• Transfer Cases

• Electronic LSD and Torque

Vectoring Systems

• HEV and Electric Drive

Systems

• AWD Electronic Controls

and Systems Integration

Transmission Systems

• DualTronic® Systems for Dual

Clutch Transmissions

• Transmission Control Modules

and Solenoids

• High Pressure Transmission

Control and Actuation Systems

• One-way Clutches

• Friction Plates

TorqTransfer Systems

A Portfolio of Leading Automotive Technology

CONFIDENTIAL INFORMATION

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BorgWarner BERU Systems supplies Original Equipment, to OEM’s, Tier I’s as well as into the Aftermarket

Diesel Cold Start

Technology

Ignition Technology

Electronic and

Sensorics

BW BERU Systems – Main Products

Pressure Sensor

Glow Plug

Vapourizer

Ignition Coil

Plug Top

High Temperature

Sensor Cabin Heater

Self Regluating

Glow Plug

Glow Plug / Heating

Control Module

Instant Start Glow

Plug

Intake Air

Heater (IAH)

High Frequency

Ignition Ignition Coil

Pencil

Dual Coil

Ignition

CONFIDENTIAL INFORMATION

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Cabin Heater Application

Product Description:

The cabin heater heats up the cold air after engine cold start in winter time.

It is located in the Heating-, Ventilation, and Air-Conditioning-Unit (HVAC),

just behind the coolant heat exchanger.

Gen I

(Electronic)

Gen II

(Mechanical)

Gen III

(Mechanical

& Electronic

Product:

Cabin Heater based on PTC (Positive Temperature Coefficient) Technology

CONFIDENTIAL INFORMATION

10

BorgWarner BERU Cabin Heater Product Portfolio

Low Voltage for Vehicles with ICE (Internal Combustion Engine, 12V - 62V)

High Voltage Heaters for Electric- & Hybrid Vehicles ( up to 450 V)

Standard

Mechanical Cabin Heater

500W - 1kW

Gen I:

fin design

Gen II:

extruded profile design

Compact

Mechanical Cabin

Heater

100W – 400W

Air 5 kW Liquid 5,5 kW

Standard

Electronic Heater

1kW – 2kW

Gen I design,

Interfaces:

PWM, LIN & CAN

Standard

Electronic Heater

1kW – 1.2kW

Gen III design,

Interfaces:

PWM, LIN & CAN

CONFIDENTIAL INFORMATION

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BorgWarner PTC Cabin Heater Customer Overview

Product Brand Vehicle HVAC Supplier Electronic

B9 Yes (400V)

MQB

C7 (A6-4F)

PQ35

No

No

No

C1 MCA

C1

Y55x

Yes

Yes

Yes

X250 Yes

X61B No

Airscarf SL No

P356, P473 Yes

Cursor & V No

CONFIDENTIAL INFORMATION

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BorgWarner BERU: High-Voltage PTC Cabin Heater (Air)

Product Description:

the HV PTC Heater for air replaces the coolant heat

exchanger and is the only heat source for passenger

comfort in the car

Technical Overview:

• electrical power from 3 kW up to 5 kW @ 200 V – 400 V

• software controlled power regulation

• developed according HV standards, tested with 2000 V

• galvanic isolation between high voltage side (power)

• and low voltage side (control)

• connection to all kind of vehicle interface networks:

• PWM, LIN-Bus and CAN-Bus

Benefits:

• closed loop software controlled

• homogeneous temperature profile

• no power degradation over lifetime

• diagnostic capability

• self regulated max. temperature due to PTC effect

Coolant heat exchanger HV PTC Heater Air replaced

CONFIDENTIAL INFORMATION

BorgWarner HV Air PTC Heaters

Gen 2 3 KW 4 kW Demo

BMW E-Mini

Demonstration Vehicles

2008 IAA Frankfurt 2011 since 2012

4 kW Series

BRABUS EV 4WD

Demonstration Fleet In Field

PSA Partner (above) & Berlingo

CONFIDENTIAL INFORMATION

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Engineering Skills

• Materials & Applied Physics – Barium titanate (PTC), Platinum rhodium (Sensors)

• Mechanical Engineering – Concept proposal, 3D Modeling, Thermal and Stress Analysis

• Electronic Engineering – Embedded Hardware and Software development

• Product Testing and Validation – Design and Process Validation

• Quality Engineers – ISO/TS 16949 – Quality Walk, DFMEA, QFD

• Manufacturing and Production Engineering

• Program Management

CONFIDENTIAL INFORMATION

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Non Technical Skills

• Communication – internal and external

• Financial Understanding – DCF for each RFQ

• Design <->Manufacturing relationship

• Team player – ability to work within a team

• Common Sense !

CONFIDENTIAL INFORMATION

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Thank You

better fuel economy

reduced emissions

great performance