Emissions Control Technologies

Compact exhaust system for range-extender vehicles

Faurecia has developed a complete compact exhaust system for gasoline engines that serve as range extenders for electric hybrid vehicles. Instead of the traditional vehicle's long exhaust line, the compact exhaust system is designed to fit into a relatively small envelope of space. It consists of a combined manifold and catalytic converter (maniverter) and two separate mufflers.

Turbo-manifold and close-coupled converter

Faurecia has created a lightweight fabricated twin-scroll type manifold, with air-gap insulation, and a close-coupled converter. Together they provide more torque and power, as well as lower fuel consumption. The twin-scroll manifold helps reduce the power-production lag time inherent to turbos. Additionally, the catalytic converter is closely coupled with the manifold, helping ensure that the converter lights off promptly and properly.

Hydroforming

With hydroforming, a tubular part is inflated inside a tool by a pressurized liquid to give it a pre-defined shape. This technology is now being used by Faurecia for muffler shells to provide a perfect underbody fit. It allows more design freedom to make oblique inlets or outlets, and to use variable wall thicknesses.

Ammonia Storage and Delivery System (ASDS)

At the LA Auto Show, Faurecia is presenting the ASDS (Ammonia Storage and Delivery System), its breakthrough nitrogen oxide (NOx) reduction technology for diesel engines.

The Faurecia ASDS is a pure ammonia selective catalytic reduction (SCR) system – as an alternative to liquid SCR systems – that delivers very precise amounts of ammonia to a catalyst in the exhaust line. This lighter-weight technology enables highly efficient removal of NOx from diesel engine exhaust gases for both passenger cars and commercial vehicles.

Sound design

The exhaust sound adds a touch more distinction to a vehicle's brand image and even allows enthusiasts to identify a particular sports car just by its recognizable way of appealing to the ear. Faurecia is able to model the sound of an exhaust system, especially through the design of its muffler. The inner structure of the muffler's walls and tubes shape the sound as certainly as the walls and tubes of a brass musical instrument.

Faurecia is actually able to design the sound of a particular vehicle platform's exhaust system using simulation and computer-aided design technology. As a result, Faurecia has significantly shortened the development time of its exhaust sound design and has lowered production cost.