SAMPLE: Engine cooling systems intelligence service. Generated: April 9, 2018

Transcription

1 SAMPLE: Engine cooling systems intelligence service Generated: April 9, 2018

2 Table of contents Table of contents Introduction... PESTER Analysis... Political... As fuel economy standards become more stringent, manufacturers believe that the need for recovering any waste heat has become paramount... Despite the stricter requirements being applied to internal combustion engines to make them more fuel efficient it appears that diesel and gasoline powertrains will still continue to power a large percentage of passenger vehicles over the next decade... Economic... The automotive engine cooling sector is driven by the same factors affecting the rest of the first tier of the industry... The challenge for suppliers will be to meet demands from automakers for improved engine efficiency and output, as well as respond to rising production of diesel vehicles and direct-injection and turbocharged gasoline vehicles.... Social... In terms of social trends and legal regulations, the supply sector will continue to face demands for improved fuel efficiency due to surging gasoline prices and stricter fuel consumption regulations.... Technological... For the time being, however, there is some debate over which cooling concept will gain acceptance for lithium-ion batteries? Cooling based on refrigerant or coolant or air?... Moving away from the internal combustion engine to the electrified powertrain and lithium-ion batteries, some clear trends are emerging.... Not only are auto powertrain cooling parts becoming smaller but there is a clear trend toward more component integration.... The increasing demand for more diesel, turbo-charged engines and hybrids is driving new and improved technology along with more efficient transmissions that sometimes require heating as well as cooling... There are a number of design implications on the engine cooling pack as engines become down-sized.... There has been a shift in emphasis from the previously predominant direct charge air cooling indirect charge air cooling assisted by the coolant.... Environmental... Demands on engine cooling product performance, packaging and cost are continually increasing. In addition, automakers expect economical solutions that help reduce emissions from cars and trucks.... There a trend toward more use of electronics to try to more closely monitor engine temperature for maximum efficiency i.e. using electronic thermostats and electronic water pumps to completely take control of the heat rejection itself.... Regulatory... Emissions regulations are the primary driver for powertrain and engine cooling developments... From a packaging point of view, there will be a need to combine heat exchangers like the combicooler as well as wider use of charge air coolers.... Pedestrian impact regulations and insurance tests are becoming ever more stringent. Car manufacturers and suppliers therefore have to join efforts to fit the increasing number of components under the bonnet, and meet European regulations.... There is no impact from R744 air conditioning to the coolant loop in case of cabin cooling... Companies... Engine and powertrain cooling system manufacturers and products supplied... BorgWarner... Calsonic Kansei Corporation...

3 Table of contents Continental AG... Delphi Automotive LLP... Denso Corporation... Hanon Systems... Mahle-Behr... Modine... Schaeffler Group (INA-Holding Schaeffler KG)... Sogefi... Valeo SA... Webasto AG... Others... Forecasts... OE radiators... Markets... Trends... Emerging markets... Market shares... Asia-Pacific... Europe... North America... OE radiator market... Technologies... Defining the elements... Innovations... Heat exchangers... Denso's solutions... Hanon Systems' internal heat exchanger (IHX)... Webasto's solutions... Indirect charge air cooling... More use of electronics... Oil coolers... Other... Aisin Seiki's electric cooling pump... Aluminium engine cooling parts for trucks...

4 Table of contents BorgWarner Thermal Systems supplies novel fan for Freightliner... Cooling system sealant... Ford's active grille shutter... SKF's Engine Fan Support Module... Solutions for alternative powertrains... EMP supplies 'mini-hybrid' cooling system to bus maker... Thermal management systems for hybrid vehicles... Tomorrow s hybrid vehicles and cooling systems... Packaging concerns... Archive... Behr cuts tank-header overhang on Audi A5... Behr develops EGR control module for diesels... Conti-Tech Fluid Automotive develops products for fuel-cell power vehicles... Delphi's liquid cooled charge air coolers... Denso creates refrigeration cycle system for cars that uses an ejector... Denso's plant-derived resin radiator tank... New Visco coupling from Hella Behr Service...

5 Introduction Introduction Thermal energy flows are an important part of a vehicle s energy balance. Even in the most advanced diesel engines, the vehicle drive uses barely one-third of the fuel energy. The task of engine cooling is to draw waste heat out of the engine in order to allow the engine to operate efficiently. The key trends engine cooling manufacturers face are turbocharging and exhaust gas recirculation. The combination of the two will enable compliance with stricter emissions standards while offering minimum fuel consumption. Although hybrids have not really created a substantial change in the heat transfer philosophy of the engine, we asked manufacturers if this technology has created the need for additional product on the electronic side of the system. In an exclusive interview with just-auto, Dr Simon Edwards, director of advanced engineering, Engine Cooling, Behr Group, told us: Yes, there are additional cooling requirements for battery cooling and power electronics/converter cooling. Li-Ion batteries have an upper temperature limit of around Xº C. High temperatures reduce the lifetime of the battery. Under warm climate conditions the Li-Ion battery therefore has to be cooled with the aid of the air conditioning system. Converter cooling requires a coolant temperature of around Xº C. Therefore so called low-temperature radiators are required in addition to the normal power train radiator." About this service This service on engine cooling systems includes market trends, shares and forecasts as well as a technical round-up of various technologies and brief company profiles. Our manufacturer market share estimates cover global (engine cooling systems; and radiators), Europe (engine cooling), North America (engine cooling) and Asia-Pacific (engine cooling). A typical cooling system consists of an engine water jacket, thermostat, water pump, radiator, cooling fan, hoses, heater core, oil cooler and overflow, or expansion tank... 1

6 PESTER Analysis PESTER Analysis Political As fuel economy standards become more stringent, manufacturers believe that the need for recovering any waste heat has become paramount. Thus, systems like exhaust gas heat exchangers will become more commonplace. For example, Dr Prasad Kadle, director, advanced engineering, Delphi Thermal Systems told just-auto: "Engines are go... Economic The automotive engine cooling sector is driven by the same factors affecting the rest of the first tier of the industry. In particular from the product perspective, the drivers can be seen as: emissions legislation, fuel economy improvements, pedestrian protection legislation, vehicle driveability improvement, cost red... Social In terms of social trends and legal regulations, the supply sector will continue to face demands for improved fuel efficiency due to surging gasoline prices and stricter fuel consumption regulations. This is in addition to more compact and thinner radiators and other parts in response to the more stringent legislation designed to protect pedestrians... Technological For the time being, however, there is some debate over which cooling concept will gain acceptance for lithium-ion batteries? Cooling based on refrigerant or coolant or air? "Currently air is our choice for UK and most of Europe but more extreme environments require heating and cooling systems. The challenge is cost, weight and energy consumption," said Chris Baylis, tec...

7 PESTER Analysis Environmental Demands on engine cooling product performance, packaging and cost are continually increasing. In addition, automakers expect economical solutions that help reduce emissions from cars and trucks. Manufacturers have responded by trying to meet these increasing demands. That means increasing specific performance, i.e. heat rejection per unit volume or weight or adding functionality... Regulatory Emissions regulations are the primary driver for powertrain and engine cooling developments As with all parts of the powertrain domain presently developments in engine cooling are very much regulatory led, particularly with regard to CO2 and tailpipe emissions. Generally, standards in all m...

8 Companies Companies The following table lists the major engine-cooling systems manufacturers and their products.

9 Companies Engine and powertrain cooling system manufacturers and products supplied Manufacturer Engine and powertrain cooling system products Calsonic Kansei UCR (Unified Condenser and Radiator) Radiator Tank Oil Cooler Internal air cooler Motor fans Oil coolers Radiators Denso Reserve tank Radiator Cooling fan EGR cooler Inter cooler Oil cooler Cooling fan controller Coolant temperature sensor Hanon Systems Charge air cooler Water-cooled charge air cooler Pumps and valves High and low pressure EGR Radiator Cooling fan and shroud Auto transmission fluid warmer/cooler Mahle Radiators Coolant pump Low temperature radiators Charge air cooling Cooling modules Oil cooling and heating modules EGR coolers Battery cooling Thermostats and control valves Modine Radiatiors and cooling modules Battery cooling and heating Parallel flow condensers, oil coolers and combo-coolers Charge-air coolers

10 Companies Manufacturer Engine and powertrain cooling system products Oil coolers Exhaust gas recirculation coolers Liquid-cooled charge-air coolers Valeo Engine temperature management systems Charge air cooler systems EGR cooling systems Oil temperature management systems Source: just-auto

11 Forecasts Forecasts This section sets out our estimates and forecasts of OE radiators fitted to newly-assembled passenger cars and light vehicles across X of the world s largest light vehicle markets - which collectively account for more than X percent of world light vehicle production. Our forecasts range is from 2012 through to 2022 with spot forecasts for 2027 and Our forecasts are not extrapolative but dependent on the underlying drivers of supply and demand. Each forecast is based on vehicle data prepared by our partner, LMC Automotive. The vehicle data (passenger cars and light commercial vehicles) includes: North America - US, Canada and Mexico; Mercosur Brazil and Argentina; Western Europe - Germany, Italy, France, UK, Spain, Portugal, Netherlands, Belgium, Sweden, Austria, Finland and Morocco; Central Europe - Turkey, Bulgaria, Czech Republic, Poland, Slovakia, Hungary, Romania, Serbia and Slovenia; Russia; Japan; China; India; Korea; Thailand; Other Asia Indonesia, Malaysia, Taiwan and Philippines; Iran; South Africa; Australia. These forecasts are updated quarterly or as and when major changes require assumptions to be amended. Full revision history for all of our forecast pages within this section allow you to see what has changed and when.

12 Markets Markets Trends Denso believes that further innovation in cooling systems and components is required in the industry due to a range of trends. The challenge will be to meet demands from automakers for improved engine efficiency and output, as well as respond to rising production of diesel vehicles and direct-injection and turbocharged gasoline vehicles. In terms of social trends and legal regulations, says Denso, demands for improved fuel efficiency due to surging gasoline prices and stricter fuel consumption regulations, as well as for more compact and thinner radiators and other parts in response to the more stringent legislation designed to protect pedestrians are also having an impact. In response to these trends, Denso says that in the case of diesel vehicles and direct-injection and turbocharged gasoline vehicles, the company is developing optimised cooling systems by linking them with ECMs, intercoolers and exhaust gas recirculation coolers. The company s engineers are developing thermal management system products based on applied waste heat recovery, heat exchange and other technologies. Packaging the engine-cooling system is another major driver of innovation. Engine-cooling systems must fit into ever-smaller spaces under the bonnet. Given the pressure on supplier to squeeze higher performing products and systems into a smaller space under the bonnet, radiators have gradually become smaller in size. For example, a modern aluminium radiator is about two-thirds the size of a unit produced in the late 1970s. The high cost of fuel, particularly in Europe, means that designers are seeking ways of reducing the airflow in the car, which is leading towards the use of smaller heat exchangers. Not only are auto engine-cooling parts becoming smaller but there is a clear trend toward more component integration. For example, combining the condenser and radiator can save space and help cut costs. Modularity plays an important role in packaging engine-cooling systems. This approach can, of course, help cut costs and simplify the entire installation on the assembly line...

13 Technologies Technologies Defining the elements A typical cooling system consists of an engine water jacket, thermostat, water pump, radiator, cooling fan, hoses, heater core, oil cooler and overflow, or expansion tank. There are two types of cooling systems: air and water cooling. As the name suggests, air cooling systems involve fans which blow air over the engine block. According to Bosch, heat absorbed by the engine oil is dispersed by an air-cooled oil cooler mounted at a suitable position in the air stream. The noise emission level and the inefficiency in maintaining consistent engine temperatures are considered to be disadvantages compared to liquid-cooled engines. Today, air cooling is mainly used for motorcycle engines and in special applications. The oil cooler is a heat exchanger that uses an air-cooling system to maintain the optimised oil temperature of vehicle oils, including engine oil and automatic transmission oil. Water-cooled engines, on the other hand, have passages for the coolant to pass through the engine, absorbing the heat generated so it can be released through the radiator. The cooled fluid is recirculated around the engine while running. Water cooling has become the standard in both passenger cars and heavy-duty vehicles. Instead of pure water, coolants are now a mixture of water (drinking quality), anti-freeze and various corrosion inhibitors, says Bosch. An antifreeze concentration of X-X percent raises the coolant mixture boiling point to allow operating temperatures of up to XºC at a pressure of X.X bar in passenger cars. According to Behr, the cooling module consists of a number of engine cooling components, as well as the condenser which forms part of the air-conditioner circuit. The modules are put together according to the vehicle design concept, reducing development, production and logistics expenses...

14 Archive Archive This section of the intelligence service contains archived pages of significant interest, but which no longer require updating.

15 Sample forecast table Sample forecast table Market volumes of conventional radiators fitted to newly-assembled passenger cars and light vehicles, , ('000s units) Market North America X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Mercosur X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Western Europe X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Central Europe X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Russia X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Japan X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X China X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X India X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Korea X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Thailand X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Other Asia X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Iran X,X.X X.X X,X.X X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X South Africa X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X Australia X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X X.X Total X markets X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X X,X.X Source: just-auto, LMC Automotive and industry sources