Fuel Delivery Module Overview

May 2022

ITB Conference – Fuel Systems for Mobility

© BorgWarner Inc.

Fuel Delivery Modules Overview

Functional Purpose : Supplying fuel flow at specific pressure to the engine

Geometry/Configuration: FDMs come in many configurations unique for each customer

• Electric Fuel Pump

• Electronic Controller

• Fuel Level Sensor

• Pressure Regulating Valves

Product Development: BorgWarner will develop an FDM specifically for each customer

application and requirements based on

• Tank geometry

• Hydraulic and electrical connection configurations

• Customer features and function determine the design of each FDM

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• Filter & Strainer

• Jet Pump

• Fuel Regulator

• Vapor Management

© BorgWarner Inc.

Fuel Delivery Modules Current Portfolio Coverage

Applications:

▪ End Use: Automotive and Non-Automotive

▪ Fuel Type: Gas, E85, E100, M15, Diesel, and B30

▪ Fuel Injection: Port Fuel (PFI), Gas Direct (GDI), Diesel Direct (DDI)

▪ Speed Control: Single, 2-speed, Closed-loop pressure, Start-stop

Product Options

▪Module Packaging: Customized for application; single chamber tank & saddle tank option

▪ Fuel Pumps: Turbine and Gerotor; Brush and Brushless motors

▪ Fuel Level Sensors: Card & Wiper, Open and Sealed; Hall-Effect

▪ Controllers: Integrated or Stand Alone

▪ Other Content: Pressure Regulators, Relief Valves, Jet Pumps, Filters, Strainers, Vapor Management

(FLVV, GVV, ROV, FVPS)

© BorgWarner Inc.

Fuel Delivery ModulesGlobal Customer Base

Automotive OEMs ~70% of Revenue

Automotive Service and Independent Aftermarket ~20% of Revenue

Non-Automotive OEMs ~10% of Revenue

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© BorgWarner Inc.

Manufacturing & Engineering Footprint

Gurgaon, India

Rzeszow, Poland

Chihuahua, MexicoNingbo, China

Piracicaba, Brazil

Auburn Hills, MI, USA

Juarez, Mexico

Blois, France

Krakow, Poland

Tokyo, Japan

Shanghai, China

Manufacturing Plant

Technical Centers

Yongin-Si, Korea

© BorgWarner Inc.

Fuel Delivery ModulesCommon Automotive Apps

FDM Family S-5000 S-6000 S-7000

Minimum Tank

Opening Diameter

~96 mm ~130 mm ~110 mm

Minimum Tank Height ~140 mm ~140 mm ~140 mm

In-tank Filter None Lifetime, Serviceable Lifetime, Serviceable

Vapor Management ROV, FVPS ROV, FLVV, GVV, FVPS ROV, FVPS

Controller Stand alone Integrated, Stand alone Stand alone

Primary Market Brazil, Asia Pacific North America Europe, Asia Pacific

© BorgWarner Inc.

Fuel Delivery Modules

Other Automotive Applications

•Saddle Tanks are common for rear- and all-wheel drive vehicles

•Tank geometry includes a tunnel to accommodate the drive shaft

High Flow Applications (>300 lph)

•May use a Fuel

Module with

two fuel pumps

•Most

applications

are for saddle

tanks

Tunnel

Primary Auxiliary

Transfer Tube

FDMs for Saddle Tank Applications

•Fuel must be transferred over the tunnel to the primary side

•BorgWarner produces several different configurations for Saddle

TanksExample of

Alternate AuxiliaryConcept

© BorgWarner Inc.

Fuel Delivery ModulesNon-Automotive Applications

• Current Product Offerings

Mount external to fuel tank

Scooters LawnmowersGenerators

• Example Applications in Production

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Fuel Pumps

© BorgWarner Inc.

Fuel Pump Families

* Average flow at 12V and 400kPa operating condition

Pump

ApplicationLow Flow Gas Mid Flow Gas High Flow Gas Diesel

Pump Family T14 T12 TXx TRx T47 T46 G23 G23

Pump Type Turbine Turbine Turbine Turbine Turbine Turbine Gerotor HE Gerotor

Pump Material Phenolic Phenolic, Al Phenolic Phenolic Phenolic, Al Phenolic, Al Phenolic, PM PM

Pump Diameter 30 mm 30 mm 39 mm 39 mm 44 mm 44 mm 39 mm 39 mm

Motor Type DC DC DC DC DC or EC DC or EC DC or EC EC

Fuel Compatibility Gas, E20, M20 Gas, E20, M20 Gas, E30, M20 Gas, E30, M20Gas, E85,

E100, M20

Gas, E85,

E100, M20Diesel Diesel

Highest Flow* (l/hr) 60 130 100 170 200 300 300 250

Lowest Flow* (l/hr) 20 40 20 60 125 175 100 100

Integration of Fuel Pump Controllers and Pressure Sensors

© BorgWarner Inc.

Controllers - Vehicle System Interfaces

Fuel Level, Fuel Pressure, Fuel Tank Pressure, Ethanol

Concentration, Temperature

Vehicle CAN, SENT or LIN

Fuel Control Module

Pump Motor Control Signals

Fuel Flow Integrated FDM

◆ Monitors sensor signals

◆ Optimizes fuel delivery systems

Body

Control

Module

Powertrain

Control

Module

Instrument Cluster

Engine

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© BorgWarner Inc.

Controllers - Mechanical Assembly Options

FDM Flange Integrated

▪ Single assembly tunes FPC to optimize Pump

▪ Eliminates harness between FPC and Pump

▪ Minimizes distance to Pump to improve EMC

▪ Requires sealing Circuit Board from Fuel Vapors

Stand Alone- Chassis or Tank Mounting

▪ Provides greatest mounting & purchasing flexibility

▪ Should target closest distance to Pump

FDM Flange Mounted

▪ Requires additional Pass-thru Connector for Pump

▪ Serviceable

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© BorgWarner Inc.

Fuel Delivery Modules

with Integrated Controller and Pressure SensorOption 1 Option 2 Option 3 Option 4 Option 5

Controller Integrated on FDM Cover

Pressure

Sensor

Type Stand Alone Stand Alone Stand Alone Stand-alone +

Controller Integrated

Controller

Integrated

Material Ceramic Silicon Silicon Silicon

Location Not on FDM Over

FDM Cover

Under FDM

Cover

Within FDM

Cover

Within FDM

Cover

ECM Command Speed Pressure Pressure Pressure Pressure

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© BorgWarner Inc.

Production FDM with Integrated Controllers

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Brushless

Pump

Integrated

Pressure

Sensor

Gasoline Delivery Module

▪ T46 Turbine Pump Section with Brush Motor

Pressure Control

▪ FDM includes silicon-based pressure sensor that monitors output

fuel pressure

▪ PWM control of Pump Voltage supply modulates current to

maintain 400kPa at FDM output fuel port

Diesel Delivery Module

▪ G23 Gerotor Pump Section with Brushless Motor

Speed Control

▪ PWM communication with Engine Controller

▪ Engine controller demands Pump Speed (~ flow) to match system pressure requirement

▪ Pump controller includes current and temperature sensing to provide diagnostic information to Engine controller

Fuel Level Sensors and Pressure Regulators

© BorgWarner Inc.

Fuel Delivery ModulesFuel Level Sensors

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FLS FamilyOpen –

“Soft Gold”

Next Gen

Open FLS

Open –

“Hard Gold”Sealed Hall Effect

Sensor Type Card & Wiper Card & Wiper Card & Wiper Card & Wiper Hall Sensor

Card Materials Silver/Palladium Silver/Palladium Gold Alloy Silver/Palladium Not Applicable

Contact Materials Gold alloy Gold alloy Gold Alloy Silver/Palladium Not Applicable

Durability 2.3M cycles 5.3M cycles 5.3M cycles 2.3M cycles Not Applicable

Height Accuracy +/- 2mm +/- 1mm +/- 2mm +/- 2mm +/- 2.5mm

Fuel Compatibility Gas, E85, Diesel Gas, E85, Diesel, and E100

© BorgWarner Inc.

Fuel Delivery Modules

Pressure Regulators & Relief Valves

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Regulator

FamilyWCPR VSR FBRV CPR

Regulator Type Diaphragm Diaphragm Ball & SpringRubber seat &

Spring

Housing Material Steel Steel Steel Plastic

Ball Material N/A N/A Steel Rubber seat

Flow Direction Reverse Flow-thru Flow-thru Flow-thru

Fuel Compatibility All Fuels

Primary Application Automotive Motorcycle AutomotiveAutomotive /

Motorcycle

© BorgWarner Inc.

The BorgWarner Solution

•BorgWarner’s portfolio of

innovative, cost effective fuel

delivery systems offers something

for virtually any automotive or non-

automotive gasoline application.

We offer complete test and

validation, global support, and

proven global manufacturing

footprint.

•Contact Us

• BorgWarner site

• www.borgwarner.com

• Engineering Contacts

• Americas

• Chris Witherspoon–

cwitherspoon@borgwarner.com

• EMEA

• Marcin Barlowski–

mbarlowski@borgwarner.com

• Asia Pacific

• Justin Jiang –

jujiang@borgwarner.com

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