PP BorgWarner OEM 2012_GB_FIN.indd

New Cabin Heater for Electric and
Hybrid Vehicles
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EL ECT R I C MOBI L I BI L I T Y
New Cabin Heater
for Electric and Hybrid Vehicles
The extremely low waste heat produced in electric and hybrid vehicles gives cabin
heaters a key role in defrosting fogged and iced windows as well as heating
interiors. To cope with the increasing electrification of the powertrain, BorgWarner BERU Systems offers customized solutions such as the innovative liquid heater. The PTC (Positive Temperature Coefficient) is used in conjunction with water
circulation to provide the interior and the battery with the required heat.
C
oncepts for low-emission locomotion depend on efficient thermal management in electric vehicles because the electric motors and
power electronics installed there as well
as the rechargeable batteries generate
significantly less waste heat than conventional combustion engines do. In addition, just when it is needed, the heat is
usually not available. BorgWarner offers
a comprehensive range of cabin heater
products to match the requirements,
ranging from the compact mechanical
version to the electronically regulated
comfort system for water circulation
which can be flexibly adapted to meet
customer requirements and specifications and covers an output range of between 200 and 5,500 watts.
Particularly
high-performance PTC cabin heater systems are increasingly being used in hybrid and electric vehicles. They not only
have to satisfy the entire heating requirements: the restricted battery capacity and range also means they have
to consume the precise amount of
electrical energy required and no more.
The core elements of all systems
are ceramic PTC stones, which have an
extremely low electrical resistance at
low temperatures. A low resistance
means a high current flow and with it a
high output, almost 100% of which is
converted into heat. If the temperature
rises, this effect is inverted, i.e. less
heat is released. Below a certain critical
temperature, a point is reached at which
the temperature can no longer increase.
This is a basic safety function (self-protection) which is also activated if a fault
occurs in the software or hardware or in
the system. The PTC stones have had
an electrically conductive coating applied to them and are located on contact
tracks which supply the power required
for heating. Located below the contact
tracks is an aluminum oxide ceramic layer which acts as an insulation to the
housing. A plastic frame holds the
stones in the correct position for the injection procedure within an aluminum
pipe. The enclosed design rules out any
functional influences.
In cooperation with BMW, BorgWarner has developed a special highperformance ceramic register which
fleet testing conducted in the MINI E
since 2009 has shown to be ready for
production. High-voltage PTCs with a
heater output of 3,000 watts installed
in the air conditioning system and connected to the 400-volt high-voltage
electrical system of the vehicle are
used in this application.
New High Voltage PTC
Liquid Cabin Heater
Since 2011, new high-voltage PTC liquid
cabin heaters from BorgWarner with an
output of 4,500 watts have been deployed in selected electric vehicles in
the USA, Germany and China to provide
more heat and better vision. This new
generation of PTC cabin heater units
meets the OEM requirements for integration into the thermal management
system for electric vehicles. When heat-
Figures: Beru
Liquid cabin heaters are used in
conjunction with water
circulation to provide the
interior and the battery with
the required heat.
O EM SUPPL IER 2 0 1 2
The newly-developed
high-voltage PTC cabin
heater units in spiral
form have a higher
output of 5,500
watts with which
they can heat up the interior
of the vehicle in only
a few seconds.
The completely re-engineered highvoltage PTC cabin heater units in spiral
form have a higher capacity. With an
output of up to 5,500 watts, they can
heat up the interior in only a few seconds. The flexibility achieved by their
compact and lightweight aluminum and
plastic casing design means they can be
mounted at different locatiwons in the
vehicle. Like the particularly efficient independent air heaters, the liquid heaters can be connected to the 200- to
400-volt high-voltage electrical systems
of vehicles. These systems are therefore ideally suited for electric and hybrid
vehicles with different on-board voltages, and they can easily compensate for
fluctuations in the electrical system of
the vehicle by means of internal control.
In all of the systems, the high-voltage limiter is realized redundantly by
both mechanical and electronic means:
an additional contact track is located in
an enclosed pipe on the other side of
the PTC stone. This track is in turn separated from the casing by an insulating
ceramic layer. The result is a high-voltage electrical circuit which is indepen-
The main feature of the heaters with integrated electronics
is the continuously variable
heater output control. This supplies the individual heating rods
individually via power transistors by activating and deactivating the load currents in the electrical system of the vehicle in a linear fashion. A closed-loop
concept allows the heater output to be
continuously adapted to the requirements of the A/C system. Control is provided for either via PWM signals or via
conventional bus systems such as CAN
or LIN. The integrated intelligence minimizes fluctuations in the electrical system of the vehicle and monitors the battery voltage, amperage ratings, power
transistors and heating rods. This as well
as further diagnosis data is stored externally in an EEPROM, where various editable cabin heater parameters are also located.
BorgWarner BERU Systems
is one of the leading global manufacturers of diesel-cold-start technology and ignition technology for
the automotive industry. Furthermore, the company provides electronics and sensor solutions for
enhanced comfort and safety in
numerous engine and vehicle
applications – e.g. sensors for
applications in engines as well as
in the drive chain and exhaust-gas
lines. We are guided by 100 years
of technological experience and
our will to innovate. BorgWarner
BERU Systems GmbH counts
almost all automotive and engine
manufacturers across the globe to
its customers.
Our modern technologies are
instrumental in lowering fuel consumption, reducing emissions and
improving performance. BorgWarner BERU Systems GmbH is a
business unit of BorgWarner Inc.
BorgWarner, based in in Auburn
Hills, Michigan, is a global technology leader in the field of hightech components and systems for
the powertrain. The company
operates manufacturing and technical facilities at 59 locations in 19
countries.
The new cabin heater technologies
are based on more than ten years of
experience in heat generation using
PTC elements and the relevant control
electronics supplied by BorgWarner
BERU Systems. n
Translated by BorgWarner
j
BorgWarner BERU Systems GmbH
www.beru.borgwarner.com
Stephan Weinhold is
Product Manager for PTC
Cabin Heaters, BorgWarner BERU Systems in
Ludwigsburg
BorgWarner
BERU Systems GmbH
Mörikestr. 155
71636 Ludwigsburg, Germany
Phone: +49 7141/ 132-0
Telefax: +49 7141/ 132-350
Web: beru.borgwarner.com
email: © Carl Hanser Verlag, München. 2012. All rights including reprinting, photographic reproduction and
translation reserved by the publishers.
technology@borgwarner.com
P r i n te d i n Ge r m a n y - 1 . 1 1. 1 2 - Be s te l l - Nr. 5 00 0 0 0 1 1 2 0
ing the vehicle interior, the
high-voltage PTC liquid
cabin heater operates
practically without any
losses whatsoever. While the interior of
the vehicle is being heated, the heater
with its water circulation is also responsible for conditioning the vehicle‘s rechargeable battery, allowing it to boost
the performance and service life of the
latter.
Closed Loop Concept
107
COMPANY PROFILE
dent of the casing and
in which the stones
are located. On the
electronics side, the
high-voltage power circuit is galvanically isolated from
the low-voltage control circuit. Redundant current
measurements (hardware
and software) as well as overvoltage detection provide additional safety.
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4 014427 139454
Printed in Germany · 1.11.12 · Bestell-Nr. 5000 001 120
BorgWarner
BERU Systems GmbH
Mörikestrasse 155
71636 Ludwigsburg/Germany
Phone: +49 (0) 71 41132-0
Fax: +49 (0) 71 41132-350
E-Mail: technology@borgwarner.com
beru.borgwarner.com
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