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| CO2 and Woco = WOCO2
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With the core statement: "Woco develops and manufactures components which improve the acoustic comfort, safety and efficiency of vehicles. Woco products therefore contribute to environmental relief through noise reduction and a reduction in consumption." And directives anchored in environmental values: "The corporate group has an obligation to protect the environment. Woco develops and manufactures products which actively avoid environmental stress and ensure environmental protection throughout the entire product lifecycle." The decrease in consumption and related reduction in the CO2 emissions of vehicles is addressed as a matter of the highest priority.
Woco develops and produces product solutions for CO2 reduction in vehicles in the Automotive Acoustics, Automotive Actuators and Polymer Technics Automotive business units in the following areas:
Weight reduction through consistent substitution of plastic for metal
Development of product solutions to reduce aerodynamic drag
Products that play an active part in thermal energy management
Components and modules for downsizing strategies for drives
with charging systems
Reduction of flow resistance in intake and exhaust systems
Development of polymer systems (material and products)
for CO2-neutral fuels
Product and module solutions for fuel cell drives
Innovative product and module solutions from the Business Units (BUs), automotive market
Acoustics
The following products are developed and manufactured in the BU Acoustics:
Plastic acoustic near-field shields
Plastic cylinder head covers with integrated fine oil traps
Air channeling for fuel cell drives
Foam encapsulation for noise reduction close to the source and
support of engine thermal energy management
Intake components and complete air intake systems with reduced flow
resistance
Engine-related technical components, particularly through the
substitution of plastic for metal
Components for the reduction of the aerodynamic drag coefficient
Woco supplies specific intake systems for hybrid drives. Woco has developed a system of this nature in the USA for the first hybrid vehicle from Chrysler. The special aerodynamic design of the intake system improves acoustics, including in cases of variable cylinder management. No additional conventional resonators are required. Pressure loss and flow speed are even improved when compared to the conventional serial intake, despite the extremely limited space available. Woco also develops air intakes and resonators for hydrogen and fuel cell drives.
Innovative developments with considerable CO2 reduction potential:
Turbocharger compressor housing
Woco was motivated to develop a plastic turbocharger compressor housing because products related to turbocharger air channeling, such as silencers, seals, coupling elements and valves are the focus of attention in terms of development. Substitution of plastic for aluminum achieves the following added value:
Weight reduction
Integration of silencers (intake and pressure side)
Integration of a diverter valve in the case of gasoline engines
Integration option for brackets for control elements
Integration of control housing for actuators
Integration of low-pressure exhaust recirculation systems
Material resistance to exhaust fumes
Surface characteristics (reduction of loss of flow)
Test bench and vehicle trials also confirm the potential forecast for CO2 reductions.
Actuators
The following products are developed and manufactured in the BU Actuators:
Pneumatic and electric actuators
Electric valves for vehicle cooling
Valves for urea supply in Bluetec applications
Control elements for exhaust recirculation and downsizing components
Components and systems for mechanical gear changing
Contributions to CO2 reduction are achieved through the function of components, design with optimized weight characteristics and control of thermal management strategies.
Innovative developments with considerable CO2 reduction potential:
Actuators for turbocharging in the context of downsizing concepts
Actuators for the control of cw value measures (e.g. brake venting or control
measures for the air flow in engine compartments)
Actuators for the control of exhaust recirculation
Water valves for the realization of complex thermal management strategies
Water valves for the support of rapid engine warm-up
Special concepts in the context of downsizing can be supported with the aid of charging systems using innovative components from BU Actuators.
Coolant valves to shut off the flow through the heat exchanger enable the control of coolant throughput in the engine and heat exchanger for targeted temperature distribution and, consequently, an improvement of cold starting characteristics. This reduces both emissions and fuel consumption. Woco supplies pneumatic actuators and electric valves. An example is an actuator with an end position sensor to actuate the by-pass flap on the exhaust recirculation radiator for exhaust recirculation. This enables bypassing of the cooling system and, consequently, the feed of hot exhaust fumes, and this in turn improves the warm-up characteristics of the engine and catalytic converter. Desired side effects are a reduction of the noise caused by diesel knock during cold starting and a reduction of cold start emissions.
Ventilation shutters are actuated using an actuator with an integrated EAS (electric air switching valve).
This reduces the loss of flow. The engine compartment flow accounts for about 15% of the cw value (flow resistance coefficient), in other words the aerodynamic drag of a vehicle. The flaps are only opened for about one third of the operation and enable a more rapid and targeted warming of the engine and, consequently, a rise in temperature and reduction of cold start emissions. A positive side effect is the reduction of typical diesel cold start knocking noise.
Pneumatic actuators help to reduce emissions in the area of exhaust treatment. Woco supplies actuators with a position sensor for this purpose for exhaust recirculation control in the so-called low pressure exhaust recirculation circuit. Exhaust fumes are extracted downstream of the particle filter and fed in again upstream of the compressor. This achieves a reduction in nitrogen oxide emissions.
The admixing of urea (AdBlue, Bluetech) to exhaust fumes also reduces nitrogen oxide emissions. Nitrogen oxide in exhaust fumes is converted to water and ammonia through SCR (selective catalytic reduction) in the case of diesel vehicles. Electric valves and special seals are required for this purpose. These are also developed and supplied by Woco. Switch valves are used for temperature control in the urea tank in the case of AdBlue systems. Coolant flow is controlled through the heating coil in the urea tank, enabling the temperature control of the urea to achieve the required urea viscosity.
Polymersystems
Products such as elastomer molded parts, precision seals, plug and cable seals made of LSR (liquid silicon rubber) and vibration decoupling products are developed and produced in the BU Polymer systems. Woco‘s own Material Development enables the realization of product and module solutions conforming to market requirements and, in particular, solutions suitable for serial production, e.g. future fuel applications (biofuels, design fuels, alcohols, etc.). Diaphragm developments and solutions also realized for gas-powered drives contribute to effective CO2-neutral applications.
Innovative developments with considerable CO2 reduction potential:
Support of rising engine compartment temperatures with elastomer materials
resistant to continuous running
Resistance of seal materials to future fuels
Resistance of materials to blow-by gases
Elastomer materials with low gas diffusion
The admixing of urea reduces nitrogen oxide emissions. Special tank filling fittings with an inlet for fuel and one for urea are part of the Woco product range.
Innovative components from BU Polymer systems enable the support of concepts relating to downsizing with the aid of charging systems, the realization of alternative drives based on gas and alcohol and the exploitation of weight and, consequently, CO2 potentials through material savings.
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| Pneumatic actuator for the control of variable turbo geometry and switching point detection
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