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All About Ignition Coils | BERU Ignition Technology Diesel Cold-Start Technology Sensors All about ignition coils Technical Information Beruparts.eu BERU® is a registered trademark of BorgWarner TABLE OF CONTENTS TABLE OF CONTENTS TRUSTED TECHNOLOGY TRUSTED TECHNOLOGY 3 OVER 400 IGNITION COILS TYPES FOR MORE THAN 12.500 THE SPARK-IGNITION ENGINE 5 DIFFERENT VEHICLE TYPES Operation of ignition coils in the spark-ignition engine 5 Requirements placed on a modern ignition coils 6 BERU Ignition Coils are developed, tested and built in Western Europe, Asia and Mexico by BorgWarner IGNITION COILS DESIGN to the OE specifications and quality standards. BERU offers a large range of Ignition Technologies for petrol AND MODE OF OPERATION 7 engines. Ignition technology terminology 7 Spark energy 9 BorgWarner supplies OEM's with ignition coils for How many ignition sparks does an engine need? 9 nearly all significant European volume applications. The company currently offers a range of over IGNITION COILS TYPES 400 ignition coils to the maintenance and repair markets – needless to say in original equipment AND SYSTEMS 10 quality. Today the market penetration of the range Canister-type ignition coils 10 in VW vehicles is 99%, in BMW Group vehicles Electronic distributor ignition coils 11 96%, in the VW Group as a whole 95% – and Double spark ignition coils 12 today the range is being continuously extended in Ignition coil rails 13 accordance with market requirements. BERU QUALITY Plug top- / pencil- / Smart- coils 13 • Products are designed by IGNITION COIL – PRODUCTION 16 BorgWarner in close cooperation with The new BERU high-tech production system 16 car manufacturers Tested quality 18 Genuine article and fakes 18 • Products are developed according to In focus: solder connection, the specifications of the automotive contacts, power transmission 19 In focus: casting compound and industry impregnation quality 20 • Manufacturing according to ISO standards WORKSHOP TIPS 21 Reasons for replacement 21 • Products are subjected to special Propper removal / installation 22 BERU tests Special tool for ignition coil replacement 22 Spark plug connector grease 23 • Manufacturing according to up to Testing and checking 24 date production methods Step-by-step defect identification 25 BERU Ignition Coils are SELF-TEST 26 engineered and manufactured at BorgWarner 2 3 THE SPARK IGNITION ENGINE Fewer emissions, lower fuel consumption, In particular, BorgWarner runs its own higher ignition voltage, restricted space in R&D departments at its Ludwigsburg, the drive unit and engine compartment: The Germany plant and in Asia, in which THE SPARK design demands on modern ignition coils are ignition technologies are driven forward in constantly increasing. Although the task of cooperation with the international automotive spark-ignition engines remains the same: the industry. Thus BERU ignition coils are being IGNITION ENGINE fuel / air mixture must be ignited at the right precisely adapted to the requirements of time with the optimum ignition energy so that modern spark-ignition engines such as complete combustion occurs. To reduce fuel turbocharging, downsizing, direct injection, consumption and emissions and to increase lean mix, high exhaust gas recirculation rates the efficiency, engine technologies are etc. In the process, we are able to fall back on constantly developed further – and thus also a whole century of valuable experience as an the BERU ignition systems. ignition technology expert. OPERATION OF IGNITION COILS IN THE SPARK- IGNITION ENGINE OE BUSINESS Optimum ignition of the compressed fuel / air mixture has been one of the greatest challenges for designers BorgWarner (manufacturer of BERU products) has an international since the early days of engine construction. In the reputation for delivering innovative ignition solutions that meet case of ignited sparked engines, this conventionally An ignition coil must be exactly attuned original equipment (OE) manufacturer standards. occurs in sequence with the compression cycle by an to the respective ignition system. The electrical spark from the spark plug. So that the voltage required parameters include: BorgWarner is delivering OE Ignition Coils, also for recent can make the jump between the electrodes, a charge applications such as those displayed (depending on the engine), must first be accumulated by the vehicles' low voltage • The spark energy, which is available to which are delivered to the aftermarket via Federal-Mogul Motorparts electrical system, then stored and finally discharged at the spark plug under the BERU brand. the spark plug at the ignition timing. • The spark current at the time of the spark discharge This is the job of the ignition coil as an integral part of • The combustion duration of the spark at • (05-2010 ), Audi A1 1.2 → the ignition system. the ignition plug A3 1.2-1.8 (08-2000→05-2013) • The ignition voltage under all operating conditions • Seat Ibiza II/III/IV 1.2-2.0 (05-2000→) • The spark count at all speeds • VW Golf IV/V/VI 1.2-2.0 (08-1997→12-2013) • BMW X3 2.0-3.0 (01-2004→) • Citroën C4 1.4-1.6 (07-2008→) • Ford Kuga 2.0 (09-2014→) • Mini 1.4-1.6 (09-2006→10-2016) • Peugeot 208 1.4-1.6 (03-2012→), 3008 1.6 (06-2009→) • Volvo S40 1.6 (01-2005→12-2012) • Mercedes-Benz G-Class 3.2 - 5.5 (07-1997→) Spark-ignition engines with turbocharger or direct fuel injection require higher spark energies. The high voltage connection between ignition coil and spark plug must be functional and safe. This is where BERU comes in with high-quality ignition cables with suitable contacts or high-voltage ignition coil connectors. 4 5 THE SPARK IGNITION ENGINE IGNITION COILS DESIGN AND MODE OF OPERATIONS IGNITION COILS DESIGN AND MODE OF OPERATION IGNITION TECHNOLOGY TERMINOLOGY Ignition coils work on the transformer principle. They As soon as the primary coil circuit closes, a magnetic THE DEMANDS PLACED ON A MODERN basically consist of a primary winding, a secondary field is generated in the coil. Induced voltage is winding, the iron core and a housing with isolation generated in the coil by self induction. At the time IGNITION COIL material, nowadays two-component epoxy resin. of ignition, the coil current is switched off by the Ignition coils in the ignition systems of modern cars generate voltages of up Plug shaft ignition coils are ignition output stage. The instantaneously collapsing to 45,000 V. It is essential that misfiring – and as a consequence incomplete mounted deep in the engine On the iron core of individual thin steel sheets two coil magnetic field generates a high induction voltage combustion – is avoided. It is not only that the vehicles' catalytic converter compartment and must elements are applied e.g.: in the primary winding. This is transformed on the could be damaged. Incomplete combustion also increases emissions and withstand extreme thermal secondary side of the coil and converted in the ratio of thus environmental pollution. loads. • The primary winding is made of thick copper "number of secondary windings to primary windings". wire with approx. 200 windings (diameter approx. A high voltage flashover occurs at the spark plug, Ignition coils are – regardless of the system (static high voltage distribution, 0.6mm), which in turn leads to ionization of the spark gap rotating high voltage distribution, double spark coil, single spark coil) – • The secondary winding is made of thin copper wire and thus to a flow of current. This continues until the electrically, mechanically and chemically highly stressed components of the with approx. 20,000 windings (diameter approx. stored energy has been discharged. As it jumps, the spark-ignition engines. They must perform faultlessly under a wide variety 0.063 mm) spark ignites the fuel/air mixture. of installation conditions (on the body, engine block or directly on the spark plug in the cylinder head) over a long service life. The maximum voltage Ignition coils: depends on: E electrical, mechanical, thermal, electrochemical requirements. • The ratio of the number of windings from the secondary winding to N1 N2 • Temperature range -40 °C to +160 °C primary winding • Secondary voltage to 45,000 V • The quality of the iron core • Primary current 6 to 20 A • The magnetic field • Spark energy 40 mJ up to approx. 90 mJ (at present) or 120 mJ (future) U1 U2 with same coil size • Vibration range to 55 g • E = Laminated iron core (magnetic) • Resistance to gasoline, oil, brake fluid • N1 = Windings primary side 100–250 windings • N2 = Windings secondary side l1 l2 10,000–25,000 windings • U1 = Primary voltage (battery voltage) 12–14.7 V • U2 = Secondary voltage 25,000–45,000 V Primary coil Secondary coil • l1 = Primary current 6–20 A • l2 = Secondary current 80–120 mA Schematic diagram: structure of an ignition coil 6 7 IGNITION COILS DESIGN AND MODE OF OPERATIONS IGNITION COILS DESIGN AND MODE OF OPERATIONS Control SPARK ENERGY An important performance criterion for ignition coils is on off Energy storage: During current supply to the coil, energy is being their spark energy. This determines the spark current Charging time stored in the magnetic field. Power and the spark combustion duration at the spark Ignition time on, coil is charged (primary circuit is plug electrodes. The spark energy of modern BERU Charge start closed, secondary circuit is open). ignition coils is 50 to 100 millijoules (mJ). At a specified ignition point the 1 millijoule = 10-3 J. Ignition coils of the latest Cut-off time Time current is interrupted. generation have spark energies of up to 120 mJ. This means that there is a risk of fatal injuries from touching these high voltage parts! Please note the safety regulations of the respective vehicle manufacturer. Primary current Induced voltage: Every change in current in an inductance (coil) induces HOW MANY IGNITION SPARKS Ignition timing (creates) a voltage.
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