• + Honeywell drives new reliability standards
  • + Engineers work globally to hit performance goals

Boosting Brazil’s Top Selling Pick-up

Posted 08.12.2009

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The GM S10 is a familiar sight in rural Brazil – and it’s likely to be even more visible now that the pick-up truck is setting new standards of reliability as a result of a complex turbo engineering program delivered by Honeywell. From the outset, the requirement from engine manufacturer MWM International posed challenges in what could be seen as a straightforward application: develop a wastegate turbo solution for its Sprint 2.8L high speed diesel that would cope with the harsh operating environment of Brazil’s rugged terrain, while still meeting exacting standards for performance, fuel efficiency and emissions control.

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What’s unique about this program, according to Christian Streck, Engineering Manager for Honeywell Turbo based in Sao Paolo, Brazil, is that the wastegate turbo had to withstand high exhaust gas temperatures and extremely high turbine inlet pressures – two demands that are very unusual for wastegate architecture.

To meet the challenge, Honeywell assembled an engineering team based in Brazil, calling on resources in Romania, France, UK, China and the US. The start point was a deep engineering investigation in order to fully appreciate the turbocharging requirements of the engine powering the S10. This initial effort identified three areas for special focus: turbine wheel integrity, coping with a high temperature environment and reducing noise levels related to earlier non-Honeywell turbo configurations.

boosting brazil

Over 18 months’ extensive analysis, testing and validation led to dramatic improvements in turbine wheel robustness, while special NiResist material was selected for the turbine housing to cope with the high temperatures (840-850C°) . With support from Honeywell’s world-leading vibro-acoustics and balancing centers of excellence, Honeywell engineers used its Vibration Sorting Rig – developed entirely in-house – to push the envelope in noise.

“The new S10 with Honeywell Turbo proved to be a complete success,” says Christian Streck. “What made the difference was Honeywell’s worldwide network of engineering expertise. The complex concurrent engineering drastically reduced the development time in coming up with a reliable turbo solution for Brazil’s biggest selling pick-up truck.”

The success of the GM S10 program enhances Honeywell’s already strong partnership with MWM International in Brazil, where the company is a key turbo technology provider for pick-up trucks, heavy-duty vehicles, buses and off-highway applications.

And looking ahead, Honeywell engineers are already actively engaged in numerous engine programs in advance of the introduction of Euro V emissions standards in Brazil in 2012.

Photo Credit: Alain Ernoult, GM Chevrolet Brazil, Volvo Trucks, VW Trucks