Turbo Technologies

Boosting the Worlds Boosting the Worlds Automotive Industry Automotive Industry

Global Partner. a worldwide team of 6,000 people in 20 locations including 6 global r&D centers and 10 major manufacturing sites all of whom share a commitment to partnership that defines the Honeywell way of working.

GlObAl PArTnEr

Engineering a Cleaner Future

In every corner of the world, car and truck manufacturers are being challenged to design and produce engines that are better performing, more fuel efficient and cleaner in short that are kinder to the planet.
Whatever the energy source, whether its diesel, gasoline, ethanol, hybrid, plug-in hybrid or fuel cell, one technology more than any other has the power to boost engine performance while reducing levels of CO2. Turbocharging is truly a technology in tune with the needs of the 21st century. It has the ability to redefine the dynamic between fuel economy and engine power, to help control emissions while addressing the fundamental need to ensure that driving remains a positive experience. And when it comes to maximizing the benefits of engine boosting, Honeywell Turbo Technologies the worlds largest turbo manufacturer is a key development partner for the biggest automotive brands, providing systems expertise and setting the benchmark in engine optimization through industry-leading technologies. The companys product portfolio is rooted in five decades of innovation and that includes the most significant turbo breakthrough of all for cars and trucks Variable nozzle Turbine (VnT ) technology.

H o n e y w e l l a d va n Ta g e

A Worldwide Partner for Turbo Technologies

Honeywells turbo technology boosts millions of diesel and gasoline powered passenger cars on every continent, ratchets up the torque that drives commercial vehicles and accelerates motorsports teams across the finish line.

Collaboration between Honeywell turbo engineers and their aerospace colleagues is borne of synergies that push the boundaries in diverse fields.

Adding Value Through Knowledge Transfer

The investment in innovation across Honeywells broad portfolio of businesses is creating value for auto manufacturers that goes way beyond turbocharging.
Honeywell is a leading partner in the development of wide-ranging technologies and systems that enable automotive manufacturers to meet the needs of their customers in a number of critical areas:

green diesel fuel for cleaner motoring high purity electrolyte storage units for enhanced energy efficiency fuel cell air, thermal and water management systems for better engine performance advanced vehicle technologies for added safety and security

This technological advantage drives the production of close to 10 million turbochargers every year, helping to create new standards of fuel efficiency and performance for passenger cars, medium and heavy duty trucks and off-highway equipment. All this is achieved through a worldwide team of 6,000 people in 20 locations across 14 countries including 6 global r&D centers and 10 major manufacturing sites all of whom share a commitment to partnership that defines the Honeywell way of working.

Collaboration between Honeywell turbo engineers and their aerospace colleagues is particularly valuable, borne of synergies that push the boundaries of aerodynamics, high temperature materials, thermal analysis, balancing technologies and oil-less bearing systems. This cross-fertilization of ideas also extends into the application of sophisticated design tools developed originally for aerospace but now used to predict engine boosting reliability.

refrigerants for cooling systems that are environmentally friendly oil/fuel additives that maintain and protect key engine components sensing and control systems that drive optimum vehicle performance particulate matter monitoring for cleaner emissions electronic systems integration for greater vehicle efficiency low dust, low noise friction materials for safer driving

GlObAl PArTnEr

Driving Performance and Fuel Efficiency

Tougher global emissions standards, new levels of fuel economy and challenging reductions in Co2 . These are the targets that auto manufacturers, in partnership with Honeywell engineers, have in their sights as they develop next generation diesel and gasoline engines.
The latest ultra-efficient powertrain developments stem from the convergence of mega trends over the last 15 years and are in response to spiraling fuel prices, growing environmental concern and demand for better engine performance. Central to this drive for fuel efficiency is turbocharging which, together with common rail direct injection, is the proven pathway to improving fuel consumption in diesel engines by up to 40% and by up to 20% in gasoline powertrains compared to naturally aspirated gasoline engines delivering the same power, with corresponding reductions in CO2 and much lower levels of nOx. When rotating, these elements force air at increased pressure into the engines combustion chamber. This compressed air is very hot, so a charge-air cooler reduces the temperature increasing the density and allowing more air into the chamber.
TurBoCHarger

The benefits of Turbo

Better Performance: Turbocharged engines deliver superior performance in power and torque, creating vehicles that are more responsive and safer to drive. Turbos also prevent the loss of power at high altitude, so providing significant advantages to turbocharged trucks and off-road machinery. Improved Fuel efficiency: Pumping losses, heat losses and frictional losses increase dramatically as engine size increases, whereas smaller turbocharged engines transform more of the fuel lower emissions: A turbocharger allows the air supply to the engine to be precisely controlled for optimized combustion. Turbos enable engines to be downsized without compromising performance, while simultaneously cutting CO2 levels and, when combined with complementary technologies, contributing to a reduction in nOx. and friction. As a result, turbodiesels are up to 40% more efficient and turbo gasoline engines up to 20% more efficient compared to naturally aspirated gasoline engines of the same power rating.

Why Turbocharge?
a turbo is effectively a sophisticated air pump that recycles wasted energy from exhaust gases to transform more of the fuel energy consumed into power. These gases drive a turbine wheel, which is coupled to a compressor.

energy they consume into power as they produce less parasitic heat

As a result, a larger amount of fuel can be used while maintaining the same air-fuel ratio, which enables more power to be generated from smaller displacement engines and ultimately this means better fuel efficiency.

A device that increases the power and efficiency of an internal combustion engine by using the exhaust gases to drive a turbine.

tUrbo aDVantaGe. the strategy of engine downsizing for both diesel and gasoline powertrains looks set to drive the automotive industry for the foreseeable future. that means embracing the power of turbocharging and complementary technologies.

TUrbO ADVAnTAGE

Meeting the CO Challenge

2
From Shanghai to Sydney, Paris to Mumbai, los angeles to Tokyo automotive manufacturers are being challenged to meet stringent new Co2 standards on every continent.
Stricter emissions point to a future that will demand smaller, better performing engines. This strategy of engine downsizing for both diesel and gasoline powertrains looks set to drive the automotive industry for the foreseeable future and that means embracing the power of turbocharging and complementary technologies. Currently, one in four light vehicles sold across the world is turbocharged by 2013 it will be one in three.

Gasoline
For gasoline passenger cars, turbocharged direct injection engines deliver a 15-20% improvement in fuel efficiency, broaden engine performance, optimize efficiency and flow and enhance responsiveness and safety.
Consequently, sales of turbo gasoline engines are expected to soar from under 3 million today to above 9 million by 2013, led by a tripling of demand in Europe and a six-fold increase in the U.S. and China.

Diesel
In diesel engines, the combined effect of turbocharging and common rail direct injection transforms performance on the road, while improving fuel consumption by up to 40% no wonder more than half of all light vehicles sold in europe are turbodiesels.
These factors also explain why diesel looks set to reach over 40% penetration in India and Korea and around 10% of all US new light vehicle sales by 2013. Demand for turbocharging will also be strong in emerging economies, with Indias light vehicle segment set to follow a similar path to Europe, with a rapid uptake in both the small (<1.7 liter) and micro (<1.0 liter) diesel segments. In China, diesel penetration in passenger cars is expected to grow from zero today to 6-8% of all new cars by 2013.

worldwide Turbo Penetration in light vehicles

35%

24%

a TeCHnology For THe world

Currently, one in four light vehicles sold across the world is turbocharged by 2013 it will be one in three.

TUrbO ADVAnTAGE

Global Innovator in Engine boosting Systems

Honeywells turbo technologies cover the entire diesel and gasoline passenger engine spectrum from 0.5 to 6.0 liters. For commercial vehicle operators, there is a Honeywell turbocharger for virtually every on and off-highway engine application, covering power ratings from 60hp to over 4000hp.
Although the underlying concept of turbocharging is simple, its application is extremely complex. Honeywell turbos rotate at up to 4,000 revolutions per second, cope with extreme mechanical stresses and operate in temperatures that reach up to 860C in diesel engines and 1050C in gasoline-powered vehicles. The technology portfolio ranges from free-floating and wastegate turbos through to world-leading Variable nozzle Turbine systems, twoAll these technologies are enhanced by advanced actuation systems, which deliver rapid and precise control by fully integrating turbo control and performance into the vehicles Engine Management Unit. In addition, advanced sensors optimize rotational speeds, maximizing the full operating envelope of the turbocharger. stage boosting and, most recently, an architecture that harnesses the power of two compressors and one turbine in a single turbocharger.

Vane Open

Vane Closed

T u r B o I n n o vaT o r

World-renowned VnT Technology

It was Honeywells development of Variable nozzle Turbine (VnT) technology that enabled car manufacturers to deploy fully the torque and fuel economy advantages of direct injection diesel engines. In VnT turbos, a row of moveable vanes, positioned in a ring around the inlet of the turbine wheel, allows the exhaust gas flow to be varied instantaneously in direct response to the engine requirements. As a result, the turbo supplies greater engine boost than smaller units at lower speeds yet matches the performance of larger turbos at higher speeds. VnT turbos are a feature in millions of passenger cars, as well as in light duty diesel trucks (AVnT) and medium / heavy-duty commercial vehicles (Double Axle VnT).

Honeywells breakthrough VNT technology delivers superior torque and fuel economy advantages for cars and trucks alike.

TUrbO ADVAnTAGE

Transforming Passenger Car Engine Performance

Honeywell technology is boosting more than 40 million passenger cars around the world with millions more benefiting every year.
VnT remains the most successful engine boosting system the world has ever seen. In one recent application, 3rd generation VnT, coupled with direct injection, is delivering a power rating almost three times that of the original non-turbocharged, indirect injection model while using less fuel and emitting 17% less CO2. Honeywell is also breaking new ground with two-stage turbo architecture, for example creating up to 30% more torque and 20% improved acceleration in a 4 cylinder 2.2 liter diesel engine through a parallelsequential turbo system compared to its baseline diesel counterpart. At the same time, innovative micro turbo technologies are making 2 and At the same time, turbos will remain an integral part of the solution to reduce nOx, by supplying the air demanded by Exhaust Gas recirculation systems. For gasoline engines, Honeywells high temperature expertise is confirmed through a turbo portfolio designed to meet the needs of new generation powertrains. Going forward, variable geometry technology and two-stage architecture will raise the performance bar still further, utilizing advances in high-performance bearing systems, in advanced actuation and in turbine housing design. 3 cylinder diesel engines more fuel efficient and more fun to drive.

B o oS T Fo r T H e lo n g H a u l

Truck operators feel the business benefits of turbocharging particularly when it comes to cranking up the torque but keeping control of the fuel gauge.

Pushing the Heavy-Duty Envelope

Honeywells turbo technology is a key enabler in delivering best-in-class fuel efficiency and reducing nox while improving engine responsiveness and enhancing engine braking capability.
leading the way is the AVnT turbo, a platform ideally suited to light trucks. AVnT, with integrated electronically-controlled actuation and position feedback, enables commercial vehicle manufacturers to deliver more power and more torque, improving performance on road while setting new standards for fuel consumption. Double Axle VnT for medium and heavy duty applications uses multiple turbine nozzle vanes supported by twin axles to deliver quicker transient response and enhanced engine braking. The nozzle vanes are positioned via a rotary Electronic Actuator (rEA), providing optimal response time and precise control. boreless Across the Honeywell commercial vehicle product portfolio, ball bearings significantly reduce friction by replacing a sliding action with a rolling mechanism, leading to faster response during engine acceleration. In series turbo systems, the benefits of turbocharging are literally compounded as a result of compressing air in two stages, creating significant improvements in engine thermal efficiency. titanium compressor wheels and speed sensors allow for high pressure ratio operation and ensure reliability.

THe Power To delIver

Honeywell turbo innovations have enabled passenger car manufacturers to deliver radical improvements in both fuel economy and driveability.

ProGreSS tHroUGH InnoVatIon. Honeywells commitment to innovation is redefining the concept of product development through process integration and responsive customer interaction enabling auto manufacturers to reduce lead times in the race to meet emissions standards.

PrOGrESS THrOUGH InnOVATIOn

Fast Forward into the Future

Honeywell turbo engineers have been responsible for over forty industry firsts from variable nozzle Turbine technology for passenger cars and commercial vehicles to rotary electric actuation (rea) systems that communicate intelligently with engine management protocols. Today, Honeywells commitment to innovation is redefining the concept of product development through process integration and responsive customer interaction enabling automotive manufacturers to reduce lead times in the race to meet emissions standards.
Honeywell engineers take a truly holistic view of developing new products for customers, thanks to Velocity Product Development (VPD), an end-to-end approach to accelerating program lead times. VPD harnesses the power of lean and Six Sigma tools to redefine the process for introducing new turbo products and as a result development times are being cut by around 30%. a proven track record of converting horizon-free thinking into groundbreaking turbo concepts and applications.

Turbo Timeline
1962

The track record of innovations pioneered by Honeywell and the original Garrett family of products spans five decades here are just a few of the turbo technology highlights.

Oldsmobile Jetfire Turbo rocket, fitted with Garrett T05 with integrated wastegate, is the first turbocharged production passenger car. Deere farm tractors select Garrett T04 turbochargers - the entire tractor industry soon follows suit. bobby Unser is the first winner of the Indianapolis 500 in a turbocharged car the Garrett TE06 boosted 2.75 liter Offenhauser. The Daimler benz Mercedes 300 Turbo Diesel Sl is launched with the Garrett T03 wastegate turbo. A Garrett turbocharged Saab 99, driven by Stig blomqvist, is the first turbocharged car to win a World rally event. The VnTTM Multivane is developed for the Volkswagen-Audi 1.9-liter direct injection diesel engine. This engine configuration establishes the TDI reputation. VW Golf and Audi A4 are the launch cars for the second generation Garrett VnTTM technology. bMW incorporates Garrett rEA technology in its diesel turbo V8 engine for the 7 Series. Garrett Double Axle VnTTM turbos are introduced on the DDC Series 50 bus engine. The bMW One Series is unveiled with third generation Honeywell VnTTM technology. The worlds first diesel parallel sequential dual stage turbo system makes its debut on the 4-cylinder engines of the Peugeot 407 and 607 and the Citroen C5 and C6. Honeywell turbocharged Audi Sport r10 TDI becomes the first turbodiesel to claim victory at the 24 Hours of le Mans.

1967 1968

1978 1979 1995

1998 1999 2000

VPD ensures there is much greater cross-functional engagement between marketing, engineering, manufacturing and customer service, meaning that product specification is clearly defined from the outset both by Honeywell and the customer. Advanced computer simulation speeds development and validation, leading to faster qualification, more effective use of resources and quicker time to market. This commitment to innovation underpins significant investment in developing the new technologies that will help auto manufacturers meet evermore stringent emissions standards. From variable geometry turbos for gasoline engines to sophisticated two stage systems and highly-efficient micro turbos for diesel passenger cars Honeywell has

2004 2006

2007 2008

ball bearing technology is launched in north American on-highway commercial vehicle applications. The Single Sequential Turbo for commercial vehicles harnesses the power of two compressors and one turbine in a single unit and delivers performance levels only previously possible in dual-stage engine boosting systems.

PrOGrESS THrOUGH InnOVATIOn

Maximizing Advantage Through People

Its the network that engineers the future. Honeywell Turbo r&d laboratories stretch from the u.S. to France, from China to uK, from Japan to Korea and from the Czech republic to India. They are home to 1,200 highly skilled engineers who every year commit hundreds of thousands of hours partnering with customers on test and application programs.
This investment in people, processes and in the worlds most advanced test and engineering equipment ensures that customers benefit from a seamless project pathway that stretches from turbo concept and product development through to application and launch. It is a global network that is set to grow still further in direct response to Honeywells major program successes with the worlds leading automotive manufacturers as they develop the fuel efficient powertrains needed to satisfy regional emissions standards.

This ability to envision and design turbo technologies for next generation powertrains is rooted in the fusion of human intellect and highly sophisticated computer simulation and modeling. The result is engineering support that designs the future, that harnesses the power of the best turbo brains in the world and which creates enduring competitive advantage for passenger and commercial vehicle manufacturers.

Underpinning these advances is a shift in emphasis from functional expertise to domain knowledge, an approach that ensures scientific and technical innovation is cascaded across the breadth of Honeywells industrial landscape.

Expanding the Global Engineering network

Honeywells latest addition to its global laboratory network is in
gloBal engIneerIng neTworK

The technical centers intellectual capability is world class, with over 90% of engineers holding either a Masters degree or Doctorate in engineering. This human capacity is boosted by 15 engine test cells and 7 gas stands which, together with the most advanced analytical hardware and software tools available anywhere in the world, enable the engineers to optimize the smallest margins of performance in aerodynamics, rotordynamics, materials engineering and mechanical analysis.

brno in the Czech republic strategically located near many of Europes major automotive manufacturers where a $17 million commitment is creating one of the worlds most advanced turbo centers of excellence. The center represents the biggest investment ever made by Honeywell on behalf of its growing customer base of commercial vehicle manufacturers, with 40% of capacity given over to CV turbo development and application. For passenger car makers there is a particular emphasis on next generation gasoline turbo systems.

Honeywell Turbo R&D centers are home to 1,200 engineers who turn bright ideas into winning technologies.

oPeratIonal eXCellenCe. Honeywell is adopting a fresh approach to quality and customer satisfaction through the Honeywell operating System (HoS), a unique production framework that focuses on delivering world-class manufacturing performance and productivity.

OPErATIOnAl ExCEllEnCE

Setting new Standards

a focus on excellence is part of the genetic makeup of all employees who work at Honeywell whether they are located in europe, the americas or asia. Through the Honeywell operating System (HoS), the company is literally transforming production performance and productivity ensuring that world-class quality cascades throughout the supply chain and adds value to global and regional automotive customers.
With forty experts working full time on the global implementation program, the aim of HOS is to transform manufacturing by gluing together operating processes and lean tools and techniques through wall to wall implementation. The approach is founded on process standardization, which ensures that every operator in every Honeywell turbo plant around the world conforms to common standards and practices and shares an identical working methodology.

This new business ethos joins together the companys network of production facilities and engineering centers and its generating remarkable results in quality, delivery and reliability. Its the system that paves the way for a significant increase in Honeywells annual global capacity within the next few years.

Setting the Pace in India

For Honeywells high-performance team in Pune, speed of execution and quality of production define the support being provided to automotive customers during Indias rapid economic expansion. Honeywells investment in Pune is introducing world-leading engine boosting systems to the region, while the facilitys production capacity is a key contributor to the companys global sourcing strategy. The continuous focus on quality, driven by the Honeywell Operating System, is also shared with local supply networks through partnership programs led by Honeywell supplier development teams. Moreover, the centers rich pool of engineering talent and its renowned software and computer modeling resources make Pune an important development center, with a particular focus on tomorrows micro turbo systems. All this reflects the determination of the 400 people on site to position Honeywell as the number one turbo business in India.

Customer Focus
HOS effectively focuses all production activities on meeting the needs of customers. The result is a change in culture, rooted in a greater confidence in working practices, in fully integrated customer support and in a better understanding of how each individual contributes to the performance of Honeywell and its automotive customers. The global reach of this new system goes way beyond the shop floor it is also facilitating customer teams in the move to the cross-functional support that is creating competitive advantage for automotive manufacturers.

Supply network
Honeywell o P e r aT I n g S y S T e M

HOS is being driven deep into the companys global supply chain, led by a technical development team of over 100 experts who work with key suppliers to ensure they meet the requirements of the standard for concurrent engineering. In this way, Honeywell ensures that quality, reliability and on-time delivery are embraced in every stage of the production cycle.

A unique production framework that focuses on process standardization to help deliver world-class manufacturing performance and productivity.

WInnInG teCHnoloGIeS. the latest Honeywell racing turbos owe as much to aerospace engineering as they do to automotive design. advanced materials and leading-edge technologies are taking turbocharger performance on the race tracks and rally stages of the world to higher levels.

WInnInG TECHnOlOGIES

boosted Across the Finish line

Honeywell is a key pit-lane partner for some of the worlds most successful race teams, whether on the tarmac of le Mans, the oval circuit of the Indy 500 or the gravel stages of the world rally Championship.
The turbos boosting todays race cars owe as much to aerospace engineering as they do to automotive design. Advanced materials and leading-edge technologies are taking turbocharger performance on the race tracks and rally stages of the world to incredible levels of performance. All this is in response to demands to keep it light, and keep it low light because race cars want to carry as little weight as possible and low to gain center of gravity advantages. As far as turbo weight is concerned, there have been dramatic reductions over the last decade or so as a result of new materials and improved dynamics. The use of titanium, magnesium and ultra-thin Almost all Honeywell racing turbos utilize ball bearing technology to exert the advantage of ultra-low friction and to deliver fast turbo response. In most race series, the rules define very clearly the parameters of engine design. So whether its the power, reliability and fuel efficiency demanded at le Mans or the high boost and rugged performance required by rally cars, Honeywell Motorsports engineers focus on winning by optimizing turbo performance through the application of advanced materials, leading-edge design, world-class engineering and manufacturing processes, and by providing race day support. stainless steel has reduced the weight of a racing turbo to about one third of that of its equivalent commercial counterpart.

racing Turbo Innovations

Heres how the Honeywell Tr30vgT32 racing turbo has reduced its weight from 24lb (10.89kg) in 1990 to 9.6lb (4.35kg) today.

1990 First magnesium compressor housings 1993 Introduction of ball bearing turbochargers 1994 Development of thin wall stainless steel turbine housings 1995 Aerospace grade materials used for turbine wheel

1996 Speed sensors introduced into center housing 1998 Introduction of titanium center housing 2002 Turbocharger redesign includes thinner walls 2006 Introduction of ported shroud

roll of Honor
Honeywell has boosted 14 Indianapolis 500 winners, 5 uSaC champions, 13 CarT/ Champ Car champions, 5 Pikes Peak Hillclimb overall winners, 12 world rally Championship winners, 2 FIa european SuperTruck champions and 10 winners at the 24 Hours of le Mans.
The most recent challenge for the Honeywell Motorsports team has been to develop the turbo technology for a new generation of diesel endurance sportscars. Compared to their gasoline equivalents, turbos for diesel racing engines are required to operate at significantly higher boost pressures and speeds. However, the type of compressor wheel design that gives optimal performance at high boost sacrifices flow range so Honeywell engineers developed ported shroud technology to meet race team requirements. When it comes to racing to the checkered flag, Honeywell sets the pace for technological support and for turbo technologies that get results.

Pole PoSITIon

When it comes to racing, Honeywell sets the pace for technological support and for turbo technologies that get results.

Europe

Czech republic Engineering Turbochargers brno-Slatina Tel: + 420 545 501 607 France Manufacturing Plant & Worldwide PV Engineering Turbochargers Thaon-les-Vosges Tel: + 33 3 29 81 30 00 Ireland Foundry & Manufacturing Plant Turbochargers Waterford Tel: + 353 51 376411 Italy Manufacturing Plant Turbochargers Piazzano di Atessa Tel: + 39 0872 8911 romania Manufacturing Plant Turbochargers bucharest Tel: + 40 21 408 5204 United Kingdom Manufacturing Plant Turbochargers Cheadle Tel: + 44 161 486 3000

Asia Pacific

Australia Sales Office new South Wales Tel: + 61 2 9755 3311 China Manufacturing Plant & Engineering Turbochargers Shanghai Tel: + 86 21 3865 2999 India Manufacturing Plant, Engineering & Customer Support Turbochargers Pune Tel: + 91 20 5652 4000 Japan Sales Office Tokyo Tel: + 81 3 6730 7070 Manufacturing Plant & Engineering Turbochargers Saitama Tel: + 81 495 72 4151 South Korea Sales Office Seoul Tel: + 82 2 3483 5024 Manufacturing Plant Turbochargers (Ansan) KyungKi Tel: + 82 31 497 0011

Americas

brazil Manufacturing Plant, Engineering & Sales Turbochargers Sao Paulo Tel: + 55 11 2167 3000 Mexico Manufacturing Plant Turbochargers Mexicali b.C. Tel: + 760 482 2166 Manufacturing Plant Thermal Systems Mexicali b.C. Tel: + 760 355 3500 United States Worldwide CV Engineering Turbochargers Torrance, CA Tel: + 1 310 530 1981 North America Customer Support and Technical Center Plymouth, MI Tel: + 1 734 392 5500

Headquarters

Worldwide Headquarters for Honeywell Turbo Technologies Honeywell Technologies Sarl Z.A. la Pice 16 1180 rolle Switzerland Tel: + 41 21 644 2700 Fax: + 41 21 644 2720 www.honeywell.com/turbo

worldwide Headquarters for Honeywell Turbo Technologies Honeywell Technologies Sarl Z.A. la Pice 16 1180 rolle Switzerland Tel: + 41 21 644 2700 Fax: + 41 21 644 2720 www.honeywell.com/turbo September 2008 Printed in USA 2008 Honeywell International Inc.