April 22, How to develop the product in remanufacturing today and in the future? Research and Development at Borg Automotive

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2 1 How to develop the product in remanufacturing today and in the future? Research and Development at Borg Automotive by Marcin Zięba Group Production Director & Grzegorz Pawłowski R&D Manager April 22, 2016

3 1. About Borg Automotive 2. Research and Development at Borg Automotive 3. Mechatronic developments 4. Reverse engineering in Research and Development - Product understanding - Communication understanding - Diagnostic methods - Tools - A car - real environment - Spare parts 3D printing - Durability tests - Quality assurance 4. Next developments 5. Future developments 2 Agenda

4 2015 Remanufacturer of the year! 3 Top player in remanufacturing

5 4 60+ Employees Sales & Administration 1,000+ Employees A/S, AC & BC 120+ Employees Steering & EGR Locations

6 Units sold 5

7 6 Fulfills OE requirements Every unit is individually tested Undergoes visual inspection Full two year warranty on all products. Warranty is not limited to specific mileage. Benefits

8 7 As we cover one the widest ranges in the independent European Aftermarket, we can provide you with both fast movers, as well as the more exotic units. This means that you can reduce lost sales, as well increase the perception as the go to distributor of you customers. Benefits

9 We minimize CO2 emission and energy consumption by 80% 8 Environment

10 The remanufacturing process 9

11 Mission 10 People Development Product & Process Development Vision Borg Roadmap Strategy Quality Assurance Cost Management Customer Service Support processes Borg Production System delivers power to improve the quality by optimizing processes and eliminating wastes in any aspect of Borg s organisation. Lean Culture Safety & Environment Borg Values Borg Production System

12 Goals: 11 To develop the right know how in BA organization to enable remanufacturing of any automotive part with embedded mechatronic systems To follow the automotive trends in our industry To master new products using reverse engineering methodologies To develop new diagnostic tools To develop new test benches Research & Development

13 Solenoid with electronics control unit StARS Voltage regulators LIN Voltage regulators LIN2 Voltage regulators BSS The range of mechatronic units at Borg Automotive 2013 Voltage regulators LIN2A Voltage regulators LIN2B 2014 Electro hydraulic power steering pumps Electric power steering columns 2014 i Stars Voltage regulators LIN2C 2015 Electric power steering racks 2015 E compressor EPB Developed mechatronic products

14 Step 1st - Applications 13 How does it work? How can we diagnose it? How can we repair it? Specification not available! Audi A6 SQ5 2.0 TDI; CTUD CTXA; 2013 Citroen Berlingo II 1.6 Hdi; 9HF DCGD; 2012 Hyundai I CRDi; D4FD; Reverse engineering product understanding

15 Step 3 rd Communication network topology 14 Step 2 nd Functions in the vehicle: Charging Motor starting Energy recovery.. Reverse engineering product understanding

16 Step 4 th Communication waveform 15 Step 5 th Single frame Step 8 th Specification Step 6 th Data bytes Step 7 th Byte 0 meaning Reverse engineering communication understanding

17 16 Communication data capturing Trial installations Faults simulation Durability tests at real conditions Diagnostic Reverse engineering with car real environment

18 data capturing data interpretation data storing bus simulation diagnostic and testing 17 capturing and displaying multiple signals analyzing of communication protocols e.g. CAN, LIN, SPI, I2C Logic analyzer Reverse engineering tools Software tool (CanOE) Oscilloscope

19 18 V Electronic diagnostic Vibrations FFT analysis Communication diagnostic Diagnostic methods

20 Spare parts development 19

21 Self designed, developed and built testers 6 machines controls products durability 24h per day Min cycles for brake calipers Min start cycles for starters Min 500h for compressor Min 1.000h for alternator 20 Durability tests the confirmation!

22 Advanced test procedures Energize 2000, 2000 If P12=0 then NOLAMP SetSpeed 0 RelayOFF 256 Delay 2 Communication interfaces Test benches 21 New testing methods Quality assurance

23 Electric parking brakes with motor control sensors 22 New communication standards Synchronous active rectifier (SAR) Products for mild hybrid cars Next developments

24 e compressor e brake pump? 23 e parking brake? e cooling pump e power steering rack From conventional to electric Future developments

25 The one part of the whole 24

26 Thank you for your time and patience. We welcome any feedback. Please feel free to ask anything. 25 M: G: Thank you