Eco-friendly automotive soloutions Pierburg

ECO-FRIENDLY AUTOMOTIVE SOLUTIONS

Pierburg s.r.o. is a specialist in emission control modules, air supply modules, throttle valves and solenoid valves. The company offers high-technology solutions, including exhaust gas recirculation systems, electrical exhaust gas flaps, as well as the many different versions of drive modules. Marco Siebel spoke with Pierburg’s vice-president Sascha Guenther to find out more.

Sascha Guenther begins: “Our company philosophy is to manufacture where the clients are. In our case the main market is clearly Europe, where our clients account for 90 per cent of our turnover – particularly those from France, Germany, the Czech Republic and the UK. We are also working on increasing profitability through further vertical integration.”

Pierburg s.r.o. was founded in 2004 in the Czech city of Usti nad Labem, between Prague and Dresden. The company is a member of the Kolbenschmidt Pierburg group (KSPG). KSPG is one of two divisions within the Rheinmetall group, a €4.6 billion world leading first-tier automotive supplier of engine components and systems.

Sascha Guenther continues: “Here in Usti nad Labem we have been fortunate to see the business grow remarkably fast. In 2007 I

From the left to the right: Richard Moulié, Supplier Development Manager, Pascal Gignoux, Supplier Development Executive Director of Powertrain and Chassis, Dr. Andreas Mueller, President Pierburg s.r.o and Rémi Robin, Sales Director Pierburg France 3rd place for the czech award for being among the top 3 fastest growing companies in the region. Mrs. Monika Satna (HR manager) as representant for Pierburg s.ro.

joined Pierburg s.r.o. in the Czech Republic as CFO, after my stay in China, where I worked for four years. Today I’m also responsible for Operations, Finance and HR.

“While in 2010 we were 120 people generating €86 million, five years later we are 450, and for 2015 we expect our turnover to reach €270 million. Thanks to our continuing strong growth, I expect to see some 100 new faces to join us during the next couple of years. To this end, because it can be quite difficult to find qualified and highly motivated people nowadays in the Czech Republic, we will be launching advertising campaigns to attract people.”

Pierburg s.r.o. in Usti nad Labem is one out of 18 Pierburg Group Global production sites, with most of the actual product development carried out in the Neuss, Germany where the Pierburg Group headquarters are located. There, the Pierburg design engineers create various automotive applications in order to reduce car and commercial diesel emissions. However, there is also a team of design engineers at the Usti nad Labem site that works on developing solenoid valve modules.

Changes in diesel engine design have contributed to something like a 10-fold decrease in emissions in the period from the late 1980s to early 2000s. The most important of these engine technologies are advanced fuel injection systems, air intake improvements, combustion chamber modifications and electronic engine control. In addition, exhaust gas recirculation (EGR) was introduced

on both light- and heavy-duty diesel engines to control NOx emissions. Low emission engine design – combined with better exhaust gas after-treatment – will continue to play an important role in future diesel engines.

Research for engine improvements is driven by both popular and legislative demands for emission reduction. Cleaner engines have become a strong selling point for carmakers, and as we have seen with the recent Volkswagen scandal, the topic influences the way the public perceives a brand. Pierburg develops and manufactures the emission and air-flow restriction hardware: exhaust gas recirculation (EGR) systems, electrical exhaust control valves (E-ECV), actuators & throttle bodies, secondary air systems (SLP) and solenoid valve modules (SV Modules).

Solenoid valve modules

Solenoid valve modules control actuate pressure or vacuum for devices such as variable geometry turbochargers, and turbocharger wastegates. They are also used for any other device that is operated by pressurised air, such as pneumatic SLP valves and EGR bypass valves. Solenoid valve modules optimise the deceleration of the vehicle and ensure the fuel supply and drain the engine when switched off. Solenoid valve modules are available in both on/off types and with pulse wide modulation for smooth regulation of control pressure. Other applications for closed-loop pneumatic control circuits include activated carbon filter shut-off valves for onboard diagnosis, shut-off valves for direct-fuel injection on gasoline engines and electric switchover valves for such jobs as flap control and secondary air systems.

Sascha Guenther: “Until recently we were mainly manufacturing and selling electro motor driven EGR modules. During that period we further developed our electrical exhaust control valves, further streamlined production processes and increased overall efficiency to make our products even more attractive for the highly demanding automobile industry where margins are tight. We are now ready for a production series that will run until 2023, and the electrical exhaust control valves currently make up over 50 per cent of our total sales.”

Electrical exhaust control valves

Electrical exhaust control valves are used to control the exhaust gas mass flow that leaves a turbo outlet. An electrical exhaust control valve is used on the engine during periods of low crank-shaftload or speed to increase the pressure after the turbo outlet, thereby increasing the temperature of the exhaust stream, warming the DPF and oxidation catalysts. It can also be used to assist the engine brake and for shift assist, particularly in commercial and off-highway applications. Exhaust flow is controlled through an actuator operating on a butterfly valve, which will meter flow as commanded by the ECU.

Sascha Guenther concludes: “Renault and Volkswagen recently placed orders for the production and delivery of the next generation electrical exhaust control valves. These contracts will generate approximately €100 million per year until 2023. In 2016 we are planning to build a 4000m2 extension to our existing production site of 11,000m2, and we are looking to hire some 100 people during the next couple of years.” n