Usp Booklet

PowertrainProductsBenefits andTechnical Information

The Powertrain Division integrates innovative and effi cient system solutions for vehicle powertrains within the automotive supplier Continental AG. These systems increase performance and driving comfort while at the same time lowering consump-tion and emissions.

As a partner of the automotive industry, the division develops and produces a compre-hensive range of products at more than 60 sites around the world. These include gas-oline and diesel injection systems, engine man-agement, transmission control units including sensors & actuators and fuel supply systems as well as components and systems for hybrid and electric drives.

2

8 System Overview

8 Gasoline Piezo Stratifi ed Turbo Direct Injection System 10 Gasoline Solenoid Turbo Direct Injection System 12 Gasoline Port Injection System – Flex Fuel 14 Diesel Piezo Common Rail Injection System

16 Engine Systems – ES

18 ECU Gasoline Solenoid Direct Injection 19 ECU Gasoline Solenoid Direct Injection NAFTA 20 ECU Gasoline & TCU Solenoid Direct Injection 21 EMS 3 Engine Management System Platform 22 ECU Gasoline Port Injection 23 ECU Gasoline Easy-U Port Injection 24 ECU Diesel Piezo Common Rail 25 ECU for Light Duty Engines (Emerging Markets) 26 ECU Platform for Commercial Vehicles 27 ECU Diesel Heavy Duty Engines 28 ECU Aftertreatment Control 29 Gasoline High Pressure 1-Piston Pump 30 Diesel High Pressure 1-Piston Pump 31 Diesel High Pressure 3-Piston Pump 32 Gasoline Piezo Injector 33 Gasoline DI XL2 Solenoid Injector 34 Gasoline DI XL3 Solenoid Injector 35 Gasoline Deka VII Fuel Injector 36 Diesel Piezo Common Rail (PCR) Injector 37 Diesel PCR New Generation Injector 38 Deka SCR Injector 39 Deka Injector for Diesel Dosing into Exhaust Gas 40 Gasoline Turbocharger

Product Applications

3

Passenger Car Application

Light Duty Commercial Vehicles Application

Medium / Heavy Duty Commercial Vehicles Application

Two-wheelApplication

AgriculturalEngines

Powertrain Products

Our road tosustainable mobility

Content

4

70 Sensors & Actuators – S & A

72 Actuators 72 Air Control Valve (ACV-S) – Economy Line 73 Air Control Valve (ACV-S) – Performance Line 74 Air Control Valve (ACV-S) – MD/HD CV Line 75 Air Control Valve (Smart ACV) 76 Brushless DC Drives High Efficiency 77 Canister Purge Solenoid (CPS) 78 Canister Purge Solenoid (CPS) – High Flow 79 Digital Linear Actuator for Idle Control Valve – Generation I 80 Digital Linear Actuator for Idle Control Valve – Generation V 81 Electric EGR (EEGR) 82 Electronic Throttle Control (ETC) – Economy Line 83 Electronic Throttle Control (ETC) – Perform. Line 84 Exhaust By-pass Valve (EBV) 85 Exhaust Control Valve – High Pressure 86 Exhaust Control Valve – Low Pressure 87 Exhaust Throttle Valve (ETV) 88 General Purpose Actuator (GPA) 89 Linear Purge Valve (LPV) 90 Pump (EWP) – Electrical Water Pump 91 Pump (SCP) – Smart Coolant Pump 92 Pump (TOP) – Transmission Oil Pump 93 Variable Lift Control Actuator (Brushless DC)

94 Sensors 94 Door Handle Sensor 95 Fluid Level – Oil Level Switch 96 Fluid Level Sensor – Capacitive QLT 97 Fluid Level Sensor – Ultrasonic

Content

5

Powertrain Products

42 Hybrid Electric Vehicle – HEV

44 Power Electronics 45 Modular Li-Ion Energy Storage System 46 High Voltage Axle Drive System 47 High Voltage Side-Mounted Starter Generator 48 Motor Control Unit for Hybrid/Electric Vehicles 49 14 V Modular Power Net System

50 Transmission – TR

52 Control Unit for Double Clutch Transmission 53 Control Unit for Double Clutch Transmission 54 Control Unit for Double Clutch Transmission 55 Control Unit for Double Clutch Transmission 56 Control Unit for Double Clutch Transmission 57 Control Unit for Double Clutch Transmission 58 Control Unit for Stepped Automatic Transmission 59 Control Unit for Stepped Automatic Transmission 60 Control Unit for Stepped Automatic Transmission 61 Control Unit for Stepped Automatic Transmission 62 Control Unit for Stepped Automatic Transmission 63 ECU for Continuously Variable Transmission 64 EAST Transmission Control Unit 65 Control Unit for Transfer Case 66 Control Unit for Limited Slip Coupling 67 Transmission Control Unit for CV 68 Automatic Transmission Control Unit for CV 69 Transmission and Retarder Control Unit

6 7

128 Fuel Supply – FS

130 Modular Fuel Supply Unit 131 Modular Fuel Level Sensor with MAPPS 132 Code Description for Names of Fuel Pumps 133 EC Fuel Pumps (43 mm) 134 Fuel Supply Electronics 135 Modular Function Carrier (MFC)

136 Emission Technology – EMITEC

138 Emitec: A brief company profile 140 METALIT® (3-Way-Cat) 141 NOx-Adsorber 142 Pre Turbo METALIT TM 143 Compact Cat® 144 PM-METALIT® 145 SCRi®-System 146 LS-Design®

147 PE-Design®

148 Selective Catalytic Reduction – SCR: 148 – Tank-integrated Dosing System 149 – Air Assisted Dosing System 150 – Airless Dosing System 151 – Digital Dosing System

Content

Powertrain Products

Sensors & Actuators – S & A

98 Fluid Level Sensor – Passive Electrothermic 99 Fluid Quality – Flex Fuel Sensor 100 Fluid Quality – Flex Fuel Sensor, High Integrated 101 Fluid Quality – Fuel Quality Sensor 102 Hydrocarbon Sensor 103 In-Cylinder Pressure Sensor 104 Knock Sensor – Wide Band 105 Mass Airflow Sensor 106 Natural Vacuum Leak Detection (NVLD II) 107 Position Sensors: 107 – Linear Contactless (Hall Effect Technology) 108 – Linear Contactless (Inductive Technology) 109 – Rotary Contactless (Inductive Technology) 110 – Rotary Contactless (Magneto-Resistive Techn.) 111 Pressure Sensors: 111 – Fuel High Pressure (GDI and DDI) 112 – Low Press. Brake Booster Absolute (BBA) 113 – Low Press. Absolute (MAP, TMAP, BAP) 114 – Low Press. Secondary Air Absolute (SAA) 115 – Low Press. Differential, Brake Booster Gauge 116 – Low Press. Differential, Filter Control Gauge 117 – Low Press. Differential, Manifold Gauge 118 – Low Press. Particulate Filter Differential 119 – Low Press. Differential, Particulate Filter Gauge 120 Smart NOx Sensor 121 Smart Particulate Matter (PM) Sensor 122 Temperature Sensor – Coolant/Fuel/Oil 123 Temperature Sensor – High Temperature 124 Temperature Sensor – Intake Air 125 Temperature Sensor – EGR 126 Temperature Sensor – Outside Air

8 9

Gasoline Piezo Stratified Turbo Direct Injection System

1 Mass Airflow Sensor with integrated Temperature Sensor (Frequency Output) 2 Electric Exhaust Gas Recirculation Valve 3 Turbo Speed Sensor (Optional) 4 Turbocharger with Electrical Wastegate 5 Manifold Absolute Low Pressure Sensor 6 Electronic Throttle Control 17 Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor 8 Exhaust Bypass Valve 9 Gasoline DI Piezo Injector 10 In-Cylinder Pressure Sensor (Optional f. CAI)

11 Single Coil Ignition 12 Dual Variable Camphaser 13 Active Camshaft Position Sensor 14 Natural Vacuum Leak Detection (NVLD II) 15 Hydrocarbon Sensor for Canister Purge 16 Canister Purge Solenoid 17 Low Pressure Fuel Pump (Demand Contr.) 18 Gasoline High Pressure Pump 19 Fuel High Pressure Sensor 20 Fluid Ultrasonic Level Sensor 21 Coolant (Water) Temperature Sensor 22 Knock Sensor 23 Active Crankshaft Position Sensor (also with Direction Detection) 24 Linear O2 Sensor 25 3-Way Catalyst 26 Binary O2 Sensor 27 High Temperature Sensor 28 Deka SCR Injector with Heated Pipes 29 SCR Catalyst 30 Smart NOX Sensor

No. Technology

No. Technology

14 15 16 1917 2320 21 2218

8 10 11 12 1391 43

24 30

5 6 22 7

System Overview

25 26 27 28 29

10 11

Gasoline Solenoid TurboDirect Injection System Euro 6

1 Turbocharger 2 Manifold Absolute Low Pressure Sensor 3 Electronic Throttle Control 4 Canister Purge Solenoid 5 Flex Fuel Sensor (Optional) 6 Natural Vacuum Leak Detection (NVLD II) 7 Fuel Supply Unit 8 Gasoline High Pressure Pump 9 Fuel High Pressure Sensor 10 Fluid Ultrasonic Level Sensor 11 Active Crankshaft Position Sensor (also with Direction Detection)

12 Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor 13 Variable Lift Control Actuator and Sensor 14 Knock Sensor 15 Coolant (Water) Temperature Sensor 16 Gasoline DI Solenoid Injector 17 Single Coil Ignition 18 Dual Variable Camphaser 19 Active Camshaft Position Sensor 20 Linear O2 Sensor 21 3-Way Catalyst 22 Binary O2 Sensor

No. Technology No. Technology

11 13 1412 15 16 17

19

18

20 21 22

321

4

5

6

7

System Overview

9 108

12 13

Gasoline Port Injection System – Flex Fuel

1 Canister Purge Solenoid 2 Fuel Supply Unit 3 Flex Fuel Sensor (Optional) 4 Electronic Throttle Control 5 Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor 6 Gasoline Multipoint Injector (Heated Injector Optional)

7 Active Crankshaft Position Sensor (also with Direction Detection) 8 Knock Sensor 9 Coolant (Water) Temperature Sensor 10 Ignition Coil 11 Dual Variable Camphaser 12 Active Camshaft Position Sensor 13 3-Way Catalyst 14 Binary O2 Sensor

No. Technology No. Technology

1 2 7 8 9 10 11 12

13

14

3 4 5 6

System Overview

14 15

Diesel Piezo Common Rail Injection System

1 Mass Airflow Sensor 2 Air Control Valve 3 Exhaust Control Valve Low Pressure 4 Turbocharger with Turbo Speed Sensor 5 Exhaust Bypass Valve 6 Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor 7 Active Camshaft Position Sensor 8 Variable Camphaser 9 Diesel Piezo Common Rail Injector

10 In-Cylinder Pressure Sensor (Optional) 11 Fuel Supply Unit 12 Diesel High Pressure Pump 13 Fuel High Pressure Sensor 14 Engine Coolant or Cylinder Head Temperature Sensor 15 Active Crankshaft Position Sensor (also with Direction Detection) 16 Fluid Ultrasonic Level Sensor 17 General Purpose Actuator 18 High Temperature Sensor 19 Linear O2 Sensor 20 Deka Diesel Dosing Injector (Optional) 21 Low Pressure Differential Sensor 22 Soot Sensor 23 Deka SCR Injector with Heated Pipes 24 Smart NOX Sensor

No. Technology

No. Technology

OxidationCatalyst SCR

11 12

17 1818 18 24232219 2120

16151413

6 98 1071 2 3 4 5

Diesel Particulate

Filter

System Overview

ES

16

ES

17

Engine Systems

Engine Systems – ES

18 19

ES


ECU Gasoline Solenoid Direct Injection

q Engine Control Unit for Gasoline Solenoid Direct Injection Systemsq Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro 6, SULEV

Technical Information

q Core TC1797, 150 MHz

q Flash size 3 MB

q Interfaces 3*CAN, 1*Flexray, 1*Lin

q Injection drivers 4 SDI

q Driver outputs 63 + 3 H-Bridges

q Housing sealed IP6K9K

q Connector pins 196

q Pb-free yes

q Engine Control Unit for Gasoline Solenoid Direct Injection Systemsq Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro 5, SULEV


q Core MPC5566, 128 MHz

q Flash size 3 MB

q Interfaces up to 2 CAN

q Injection drivers 4/6/8 SDI (scalable)

q Driver outputs 44 + 1 H-Bridge



q Pb-free yes

ECU Gasoline Solenoid Direct Injection NAFTA

20 21

ES


ECU Gasoline & TCUSolenoid Direct Injection

q Engine Control Unit for Gasoline Solenoid Direct Injection Systems with integrated transmission controlq Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro 5


q Core EMS TC1767, 80 MHz

q Core TCU TC1766

q Flash size 2 MB

q Interfaces 1*CAN, 1*LIN

q Injection drivers 4 SDI


q Housing sealed IPX9K


EMS 3 Engine Manage-ment System Platform

q ECU for 3rd Gen. Engine Management Platform q Supports Gasoline, Diesel & Electrical Applications: MPI, SDI (CoSI), PDI, Flexfuel, Variable Valve Lift, Highly Charged Engines, Integrated High Pressure Pump (HPP) Control, Boost-at-crank q Ready for Euro 6


q Core Tricore & PowerPC, 80 –264 MHz

q Flash size 1– 4 MB

q RAM size 64 – 256 kB

q Interfaces 1*CAN; up to 2*Flexray up to 12 Sent; LIN

q Injection drivers 2, 3, 4, 6, 8 Piezo, Solenoid

q Driver outputs 16 – 60

q Housing Aluminum or Magnesium

q Connector pins up to 196 (300 in combination)

q Pb free yes

22 23

ES


ECU Gasoline Port Injection

q Engine Control Unit for Gasoline Multipoint Injection Systemsq Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro 5 and Euro 5+



q Flash size 1.5 MB

q Interfaces 1*CAN

q Injection drivers 3 or 4 MPI

q Driver outputs 27

q Housing sealed IPX9K


q Pb-free yes

ECU Gasoline Easy-UPort Injection

q Ready-to-use Gasoline Engine Management System for worldwide applications: Europe low budget vehicle segment, Russia, China, India, ASEAN, Middle East, South Americaq CNG variant availableq Modular and scalable system for various engine and vehicle configurations incl. Euro 5 and EOBDq Supported by local application teams


q Core MPC563, 60 MHz

q Flash size 1 MB or 1.5 MB

q Interfaces 1*CAN, 1*K-line, 1*LIN

q Ignition driver 4 internal IGBT or external

q Injection drivers 4 MPI

q Driver outputs 24


q Connector pins 96

24 25

ECU Diesel Light Duty Engines

q Engine Control Unit for Light Duty Vehicle Engines (in emerging markets)q Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro IV and Euro V Technical Information

q Core Freescale MPC5566, 80 MHz

q Flash size 24 MB

q RAM 4 MB

q Interfaces 2*CAN

q Injection drivers 4




ES

q Engine Control Unit for Diesel Piezo Common Rail Injection Systemsq Standardized, scalable and modular electronic hardwareq Chassis mountedq Supporting Euro 5 (potential for Euro 6)



q Flash size 4 MB

q Interfaces 2*CAN

q Injection drivers 4 cylinder, single bank


q Housing sealed IP5k9k


ECU Diesel Piezo Common Rail

26 27


ES

ECU Diesel Heavy Duty Engines

q Diesel engine management for Amplifi ed Common Rail and Pump-Line-Nozzle and other Solenoid Injection Systemsq On-engine mounted with damping elementsq Fullfi ll current emission requirements (EPA 2010+, Euro VI+, combined with SCR)


q Core TriCore TC1796

q Flash size 1.5 MB

q Interfaces 3*CAN


q Driver outputs 21 + 1 H-Bridge

q Housing sealed IP69K–IP67


ECU Platform for Commercial Vehicles

q Diesel Engine Control Unit for ww applicationsq Modular and scalable HW approach to cover various engine confi gurations for Euro IV through Euro VIq Supporting all current Solenoid Injection Systemq On engine mounted (with damping elements)


q Core MPC5xxx/TC17xx

q Flash size 4 MB

q RAM optional external RAM

q Interfaces 4*CAN, 2*Flexray

q Injection drivers up to 12



q Connector pins 2 x 76

q Pb-free yes

28 29

Gasoline High Pressure 1-Piston Pump

q Dry run capabilityq Mounted on top of the camshaft


q System pressure up to 200 bar

q Supply pressure 0.5 up to 6 bar

q Temperature range – 40 up to +150°C

q Control digital valve

q Drive cam driven

q World wide fuel compatibility


ES

ECUAftertreatment Control

q Cost optimal design for control of exhaust aftertreatment systems (SCR, DPF)q Control unit suitable for 12 V and 24 V battery voltageq Cabin or chassis mounted control unitq CAN interface to NOx sensor and engine control unit


q Core MPC543 Coral

q Flash size 1 MB

q Interfaces 2*CAN, 1*SAE J1708


q Driver outputs 19

q Connector pins 62

30 31

ES

q Designed for the high expectations and harsh environment of commercial vehicles


q System pressure 2,000 bar

q Design 1.02 cm3/ rev

q Max. speed at full load 4,500 rpm

q Max. radial load 2,250 N (special 4,000 N)

q Weight 6.5 kg

q ITP (Internal Transfer Pump)

q Woldwide fuel compatiblity incl. special fuels

Diesel High Pressure 3-Piston Pump


q Innovative digital metering valveq Weight and package optimized high pressure pump


q System pressure up to 2,200 bar

q Displacement 0.4 cm3/rev

q Max. speed at full load 4,500 rpm

q Max. radial load 2,000 N

q Weight < 2.4 kg

q Start/stop capability up to 240 k starts

q Worldwide fuel compatibility incl. special fuels

Diesel High Pressure 1-Piston Pump

Gasoline DI XL2 Solenoid Injector

q Improved linear flow range for turbocharged enginesq High flexibility of spray characteristics to meet the requirements of each target engineq O-Ring or metal-to-metal sealing


q System pressure 40 up to 150 bar

q Working flow range up to 20

q Static flow range 5 up to 17 g/s (at 100 bar at 70°C)

q Min. dynamic flow ≥ 4 mg/stroke

q SMD size ≥ 15 µm

q Opening/Closing min. 300 µs

q Cone angle range 35° up to 90°

q Bent angle range 0° up to 30°

q World wide fuel compatibility32 33


ES

Gasoline Piezo Injector

q Very fast & precise injection (up to 4 injections/combustion cycle)q Extended linear flow range, high flow capability




q Static flow up to 35 g/s

q Dynamic flow 14.5 mg/ injection ± 10% at 0.4 ms PW

q Min. dynamic flow ≥ 2 mg/stroke

q SMD size ~ 15 µm

q Opening/Closing time ≥ 150 µs

q Spray angle 94°/98°± 4°



34 35

ES


Gasoline Deka VII Fuel Injector

q Fast opening/closing, various packaging optionsq Flexible orifice configurationsq Low pulse width with high linear performance and low voltage sensitivity



q Fuel compatibility Gasoline & Flex Fuel (up to E100)

q Static flow rate per applic. 0.95 up to 6.0 g/s

q SMD size ~ 60 up to 100 µm with ASQUARED

q Opening time < 1.10 ms

q Closing time > 0.70 ms

q Min. linear pulse 1 up to 20 ms

q Possible cone spray 10° up to 30° spray patterns bent stream 5° up to 25° split stream 15° up to 30°

Gasoline DI XL3 Solenoid Injector

q Improved linear flow range for high-turbocharged enginesq High flexibility of spray characteristics to meet the requirements of side or central mounted enginesq O-Ring or metal-to-metal sealingq Multiple injection capabilityq No needle bouncing




q Static flow range up to 20 g/s (at 100 bar at 70°C)

q Min. dynamic flow ≥ 3 mg/stroke at 40 bar

q Max. functioning press. 260 bar

q Multiple injection min. 500 µs dwell time

q Multi-stream technology max. 8 holes

q Family layout short, long, extended


36 37

ES

q Excellent multiple injection stability due to needle direct drive and needle closed loop controlq Reduced CO2 emissionsq Enable future emission standards Euro 6 / US Tier2, US OBD conformity approvedq Outstanding low noise (NVH)


q System pressure 2,200 bar

q Min. quantity 0.5 mm3/shot

q Max. no. of injections 9

q Min. injection separation 50 µs

q Permanent leakage 13 ml/2,200 bar, no additional dynamic leakage

q Diameter nozzle holes > 90 µm

q Rate shaping Boot + Ramp

Diesel PCR New Generation Injector


q Million times field proven technology q Reduced injector leakage for low CO2 emissions and fuel consumptionq Improved injection accuracy to meet Euro 6 / US Tier2 emission standards


q System pressure up to 2,000 bar

q Min. quantity 0.8 mm3 (with quantity drift correction)

q Max. no. of injections 7

q Min. injection separation 200 µs

q Permanent leakage < 26 ml/min at 2,000 bar plus additional dynamic leakage

q Diameter nozzle holes > 90 µm

q Closed loop control (Injector Control Valve Adaptation – ICVA)

Diesel Piezo Common Rail (PCR) Injector

q Robust approach for Diesel Particle Filter (DPF) and High Efficiency NOX Trap (HENT) regenerationq Uses existing injection technologies (production control valve, nozzle design similar to DI injector)q Avoidance of oil dilution by post injection leads to longer oil change intervals, greater tolerance of bio diesel, and increased engine durabilityq Higher degree of flexibility for regeneration timingq Improved fuel economy


q Delivery fuel mass range 0.1 up to 8 g/s

q Accuracy of flow ± 7%

q SMD size 75 up to 150 µm (Diesel Fuel)

q Input pressure range 350 up to 1,200 kPa

q Max. control valve temp. 120°C

q Max. spray nozzle temp. ≥ 500°C

q System minimum pulse width 10 up to 20 ms38 39

ES


Deka Injector for DieselDosing into Exhaust Gas

Deka SCR Injector

q Single fluid airless system, compatible with purge operationq Simple and reliable delivery of urea with excellent spray performanceq Multiple spray configurations (Patented A2 and Enhanced Atomizer options available)q Increases overall system efficiency by using maximum synergies with existing technologies Technical Information q Nominal static flow Qs ≥ 0.9 g/s (500 kPa, AUS32) q Nom. dynamic flow Qd ≥ 3.0 mg/pulse (500 kPa, 5 ms pulse, AUS32) q Nominal spray angle 19 up to 31 degrees (solid cone spray) q SMD size ≥ 60 µm (500 kPa, water) q Fluid pressure range 380 up to 900 kPa q Injector body temp. 160°C max. continuous q Injector tip temp. 200°C max.

40 41


ES

Gasoline Turbocharger

q Designed for a fully integrated robotized assembly processq Outstanding thermodynamicsq Robust and reliable design


q Gasoline application up to 1050°C exhaust gas temperatures

q Engine power up to 250 kW per Turbo

q Turbine wheel Ø 30 up to 60 mm

q Air flow max. 0.3 kg/s

q Speed max. 330,000 rpm

q Integrated recirculation valve

q Electric actuated wastegate control

q Milled compressor wheel

42

Hybrid Electric Vehicle – HEV

HEV

43

HE

V

Hybrid Electric Vehicle

44


45

Modular Li-Ion Energy Storage System

Power Electronics

q Application in hybrid, electric and fuel cell vehiclesq Safety and lifetime optimized cellsq Synergy effect through modular systemq Variable cooling system


q Power: 18 kW up to 120 kW

q Li-Ion ultra high power cells

q Integrated battery management

q Integrated safety system

q Integrated cooling system

q Modular design q Control module for electric machine in hybrid electric vehicle, electric vehicle and fuel cell vehicle


q Water cooling

Inverter

q Power: up to 110 kW at 420 V

q Converts energy in both directions – drive electric machine in motor and generator mode

Converter

q Power: up to 3 kW

q Bi-directional potential free energy transport between HV traction battery and 12 V power net

q Replaces conventional 12 V generator

HE

V

Single Inverter

s Single DC/DCConverter

Inverterwith integrated convertert

HV Side-Mounted Starter Generator

46


47

q High speed asynchronous machine q High power densityq High efficiencyq Low weightq Short axial lengthq Cost-optimized


q High speed up to 18,000 rpm

q High voltage up to 150 V

q Regenerative power 5 kW continuous, 20 kW peak

q Fluid cooling

q Aluminum housing

q Special stator winding design

HE

V

High Voltage Axle Drive System

q High speed synchronous machine (externally excited)q High power densityq High efficiencyq Cost-optimized


q High speed up to 12,000 rpm

q High voltage 450 V up to 690 V

q Mechanical power 35 kW up to 70 kW continuous 70 kW up to 140 kW peak

q Fluid cooling

q Aluminum housing

q Mechanical integration of gearbox and e-machine

14 V Modular Power Net System

Motor Control Unit for Hybrid/Electric Vehicles

48


49

q Energy storage for limited regenerative braking (up to 4% CO2 reduction)q Provides second voltage level for high power applicationsq Support of start-stopq High number of load cyclesq Modular and integrated designs available


q DC/DC converter 0.4 kW up to 2.6 kW – Voltage level 14 V up to 60 V – Efficiency up to 94% – Bidirectional – Potential-free and potential-connected designs availableq Energy Storage 3.6 Wh up to 50 Wh – With Double Layer Capacitors – Includes active or passive balancingq Energy management & diagnosis (e.g. SOC, SOH)q CAN or LIN communication

q Central power train control unitq Flexible modular systemq Scalable to customer requirements


q Driver demand acquisition

q Torque demand calculation

q Recuperation during braking and deceleration

q Energy management depending on battery state of charge

q Battery charge management

q Control of cooling system

q Communication gateway

q Low quiescent current: 100 µA

HE

V

50

Transmission – TR

51

TR

Transmission TR

52 53

Control Unit for Double Clutch Transmission

q Integrated transmission control unit for dry 7-speed Double Clutch Transmissionq Mechatronic module assembled in the gearboxq Higher reliability of the electronics due to the reduced number of internal connectionsq Weight reduction due to integration


q Ceramic substrate technology

q 32-bit microprocessor

q Operating temperature: – 40°C up to +140°C

q Direct connection of actuators to the control unit

q Only one plug connection to the vehicle

q Control of BLDC motor of oil pump

q Maximum permissible acceleration

TR

Transmission – TR


q Integrated transmission control unit for wet 7-speed Double Clutch Transmission (hydraulically controlled) q Mechatronic module assembled in the gearbox


q LTCC (Low temperature co-fired ceramics) substrate for electronic components


q Integrated in transmission surrounded by transmission oil

q 11 close-loop controlled valves

q Integrated sensors: – 4 position – 2 speed – 2 pressure – 1 temperature

54 55

TR

Transmission – TR


q Integrated transmission control unit for wet 7-speed Double Clutch Transmission (hydraulically controlled)q 4 WD applications, longitudinal installation of the engine



q 32-bit microcontroller


q Vibrations up to 20g

q Integrated sensors: – temperature – pressure – speed – gear position


q Integrated transmission control unit for wet 6-speed Double Clutch Transmissionq Mechatronic module assembled in the gearbox





q Drivers: 9 solenoids (4 prop. + 5 on/off)

q Sensors: – 4 linear position – 2 speed – 2 pressure – 1 temperature – 1 transmission range sensor

56 57

TR

Transmission – TR


q External transmission control unit for wet 7-speed Double Clutch Transmissionq Hydraulically controlled


q PCB technology



q Mounted in vehicle cabin

q 9 solenoids (7+2)

q PCB screwed on aluminum plate and cover with 2 connectors of 42 pins each


q Mechatronic control unit for dry 7-speed Double Clutch Transmissionq Includes 2 BLDC motors


q PCB technology



q Power module operates 2 BLDC motors for gear actuation

q Controls 2 external clutch actuators

58 59

TR

Transmission – TR

Control Unit for Stepped Automatic Transmission

q Control unit for 6-speed Automatic Transmissionq Mechatronic module assembled in the gear boxq Integration of all transmission sensorsq Weight reduction due to integrationq Higher reliability of the electronics due to reduced number of internal connections



q E-Module based on flex technology

q Powerful 32-bit microcontroller


q Position, speed and temperature sensors integrated

q Integrated control unit for 7-speed stepped Automatic Transmissionq Mechatronic module assembled on valve body of gearbox


q LTCC substrate for electronic components



q Flex-foil for electrical interconnection to sensors and 5 pin vehicle connector

q Integrated speed and temperature sensors

q 8 power outputs for solenoids with integrated connectors

q 3 integrated speed sensors 1 position sensor




60 61

Transmission – TR

TR

q Stand-alone transmission control unit for 5-speed and 6-speed Automatic Transmission


q PCB technology


q Operating temperature: up to +105°C

q Chassis mounted

q Sealed housing

q External control unit for 5-speed Automatic Transmissionq Transmission for rear-wheel drive vehiclesq Mounted in engine compartment


q PCB technology

q 16-bit microprocessor


q Power outputs for 6 electromechanical hydraulic valves: – 2 control valves for the hydraulics of the transmission – 3 control valves for the gear changing – 1 valve for bypass converter

q Protection class: IP 50 (DIN 40050 T9)

62 63

ECU for Continuously Variable Transmission

q Integrated transmission control unit for Continuously Variable Transmission for front-wheel drive applications





q Vibrations up to 20g

q Integrated sensors: – temperature – pressure – speed – transmission selector lever

Transmission – TR

TR


q Electro-hydraulic control unit for 6-speed Automatic Transmissionq Integrated transmission control unit including manifold and solenoidsq Monitors transmission performance and com- pensates for normal wear in components such as clutch plates, so transmission performance remains consistent for the life of the transmission



q 32-bit microprocessor with external flash memory


q 14-pin vehicle interface connector system

64 65

TR

Transmission – TR

Control Unit for Transfer Case

q Control unit for high/low shift and active torque distribution of transfer cases used in four-wheel drive vehiclesq For improved traction on-road and off-road


q PCB technology

q Powerful 16-bit microprocessor


q Flame Retardant 4 (FR4) substrate for electronic components

q Power output for one actuator motor

q Protection class IP40

q Stand-alone housing with integrated cooling plate

EAST TransmissionControl Unit

q Control unit for stepped AT, CVT, DCT, hydraulic and electric AMTq Stand-alone conceptq Reduced time-to-market thanks to existing platformq Cost efficient solution


q PCB technology

q 32-bit microcontroller with internal flash memory


q Environment: engine or passenger compartment

q Flame Retardant 4 (FR4) printed circuit board substrate

q State of the art input/output stages

66 67

TR

Transmission – TR

q External transmission control module for ultrashift and autoshift applications in commercial vehicles (CV)


q Stand-alone module, transmission mounted

q 32-bit microcontroller, with up to 2.5 MB memory


q 76 way module I/O connector

q Communication via Hardwire and CAN

Transmission Control Unit for CV

Control Unit for Limited Slip Coupling

q Control unit for limited slip coupling of 4WD control applicationsq Controls a valve and feeder pump to change torque distribution between front and rear axleq Unit directly attached to 4WD coupling


q PCB technology


q Flame Retardant 4 (FR4) substrate for electronic components

q Power outputs for one valve and oil pump


q Integrated connectors for solenoid and pressure sensor

q Integrated LC-module

68 69

Automatic Transmission Control Unit for CV

q Control unit for 6-speed Stepped Automatic Transmission used in commercial vehicles (CV)q External control unitq Improved shift comfortq Reduced life cycle costsq Higher reliability


q PCB technology



q HDI organic substrate

q 10 power outputs for solenoids

q 3 VRS speed inputs

q CAN, J1708, J1850, K-Line communication

q 18 switch inputs

Transmission – TR

Transmission and Retarder Control Unit

q Control unit for 6-speed Automatic Transmission and Retarder for commercial vehicle applicationsq Control unit directly mounted on the transmission or retarderq Improved performance characteristicsq Higher service lifeq Reduced driving noise developmentq Reduced harness length and complexity


q Ceramic substrate and direct copper bonded technology



q IP6k9 housing with overmolded leadframe

q 24 V/12 V capable

q 2 x CAN-Bus and current control outputs (10)

TR

70 71

S&

A

Sensors& Actuators

Sensors & Actuators – S & A

S&A

S&

A

72 73

Air Control Valve (ACV-S) Economy Line

Air Control Valve (ACV-S) Performance Line

q Low cost, full functional range Electronic Throttle Body actuator for diesel combustion enginesq Non-contacting position sensorq Low weight, small packageq Good crash behaviorq Capable for LP EGR environment


q Temperature range intake air – 40 up to +140°C

q Temperature range environm. – 40 up to +140°C

q Excess torque > 1 Nm (13.5 V, RT)

q Response time (typ.) 130 ms (13.5 V, RT)

q Pressure range up to 3.5 bar peak

q TP diameter range 40 up to 57 mm

q High temperature Electronic Throttle Body actuator for diesel combustion enginesq Non-contacting position sensorq High torque, fast responseq Very good EMC performanceq Capable for LP EGR environment




q Excess torque > 1.6 Nm (13.5 V, RT)




S & A Actuators

74 75

S&

A

Air Control Valve (ACV-S) MD/HD CV Line

q Modular Electronic Throttle Body actuator for medium and heavy duty diesel combustion engines, capable for 12 V and 24 V systems q Non-contacting position sensorq High torqueq Capable for big TP diametersq Capable for LP EGR environment








q Intelligent Electronic Throttle Body actuator for diesel combustion engines q Integrated control unit with processor and H-bridge for DC motor on-board q Easy to integrate into existing systemsq Non-contacting position sensorq Capable for LP EGR environment








S & A Actuators

Air Control Valve(Smart ACV)

76 77

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S & A Actuators

q High efficency Brushless DC drives for use in double clutch, AWD-disconnect, Oil pumps, ...q Small packageq Low weight


q Different performance classes 50 W up to 200 W


Brushless DC Drives High Efficiency

Canister Purge Solenoid (CPS)

q Canister regeneration with a PWM solenoid q Linear flow curve, sonic nozzle flow controlq Fast response, light weight, compact sizeq Various mounting options availableq Direct manifold mount w. NVH suppression feature


q Flow at 500 mm Hg 50 up to 85 SLPM

q Nominal operating voltage 14 V

q Coil resistance 17 Ohms

q Control circuit PWM

q Operating frequency 5 Hz up to 32 Hz

q Operating temperature – 40 up to +140°C

q Total leakage at 500 mmHg < 20 SCCM

q Sonic regulated above 100 mmHg

78 79

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S & A Actuators

High Flow

Canister Purge Solenoid (CPS)

q Canister regeneration with a PWM solenoid q Linear flow curve, sonic nozzle flow control q Fast response, light weight, compact size q Various mounting options availableq Direct manifold mount with NVH suppression feature q Provides high flow for Turbo, HEV, Continuous Variable Valve Lift, Start & Stop applicationsq Check valve options available

Technical Informationq Flow at 500 mmHg 50 up to 110 SLPM

q Nominal operating voltage 14 V

q Coil resistance 24 Ohms

q Control circuit PWM

q Operating frequency 5 Hz up to 32 Hz


q Total leakage at 500 mmHg < 20 SCCM

q Sonic regulated above 100 mmHg

Digital Linear Actuator for Idle Air Control Valve

q The idle air control system provides a consistent, stable idle speed throughout the service life of the vehicle (maintenance free)q The air flow characteristic is tuned to the application needs by changing the pintle profileq The actuator (DLA) can be integrated into air induction system


q Operating Voltage 12 V (7.5 V/14 V)

q Inductance per winding 33.5 mH

q Resistance per winding 53 Ohms

q Resolution 0.04167 mm/step

q Total travel 8.5 mm (204 steps)


q Weight 110 g

q Vibration 35 up to 40 G

Gen I

S&

A

80 81

S & A Actuators

Digital Linear Actuator for Idle Air Control Valve

q The idle air control system provides a consistent, stable idle speed throughout the service life of the vehicle (maintenance free)q The air flow characteristic is tuned to the application needs by changing the pintle profileq Plastic sleeve design for partial or complete integration into a throttle body


q Operating Voltage 12 V (7.5 V/14 V)

q Inductance per winding 33.5 mH

q Resistance per winding 53 Ohms

q Resolution 0.04167 mm/step

q Total travel 8.5 mm (204 steps)


q Weight 50 g

q Vibration 30 up to 35 G

Gen V

Electric EGR (EEGR)

q Electric Actuation has faster response and more control than conventional vacuum systemsq Eliminates vacuum regulator and connecting hosesq Can be tailored to customer flow requirements


q Nominal operating voltage 13.5 V

q Current consumption at max. flow 1.0 A at 20°C

q Max. current consumption 1.5 A

q Nominal coil resistance 8.0 Ohms at 20°C

q Nominal operating frequency 90 Hz up to 175 Hz

q Position sensor supply voltage 5 V

q Response time (total stroke) < 50 ms (open to close or close to open)

82 83

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A

S & A Actuators

Electronic Throttle Control (ETC)

q High performance Throttle Body actuator for gasoline combustion engines q Non-contacting position sensorq High torque, fast responseq Very good EMC performanceq High temperature capabilities







q Leakage (at stop) < 1.7 kg/h (52 mm)


ETCPerformanceLine

Electronic Throttle Control (ETC)

q Low cost, full drive-by-wire Electronic Throttle Body actuator for gasoline combustion engines q Modular available with plastic or aluminum die-cast housingq Non-contacting position sensorq Low weight, small package







q Leakage (at stop) < 3 kg/h (52 mm)


ETCEconomyLine

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A

84 85

S & A Actuators

Exhaust Control ValveHigh Pressure

q Provides both accurate low flow precision (improves engine performance) and high volume flow (improves emission reduction) by maintaining low gas pressure dropq Non-contacting sensor, flexible output, not sensitive against magnetic fields, well known control strategy q Compact, light weighted size and water cooled additional shaft bearing to withstand high pressure pulsation


q Torque at flap: 230 Ncm

q Response time (85%): < 80 ms

q Nominal supply voltage: 13.5 V or 24 V

q Position sensor supply voltage: 5 V

q Maximum flow: up to 190 kg/h at 50 hPa

q Exhaust temperature: up to 700°C

Exhaust By-pass Valve(EBV)

q Design options available to fit customer requirementsq Easy integration into EGR coolerq Flexible housing designq Leakage to atmosphere < 0.5 kg/h at 3 barq Electrically actuated valves are also available


q Operating ambient temperature range – 40 up to +140°C

q Exhaust gas temp. 600°C (short term 650°C)

q Actuator opening – design capability range < 100 ms

q Mechanical closing – design capability range < 100 ms

S&

A

86 87

S & A Actuators

Exhaust Throttle Valve(ETV)

q Provides back pressure to ensure the low pressure EGR flowq Resistant to external aggression: stone projection, gravel, water splashes…q Resistant to corrosion using specific materials, i.e. flap housing off precision casting or welded stainless steel technology


q GPA technology used for actuation – Nominal supply voltage 13.5 V – Position sensor supply voltage 5 V

q Maximum flow up to 420 kg/h at dp 50 hPa

q Response time (t90) < 100 ms

q Exhaust gas temperature 800°C

Exhaust Control ValveLow Pressure

q Provides both accurate low flow precision (improves engine performance) and high volume flow (improves emission reduction) by maintaining low gas pressure dropq Non-contacting sensor, flexible output, not sensitive against magnetic fields, well known control strategy q Compact, light weighted size and water cooled (option)q Adapted to corrosion requirement for LP EGR path


q Response time (t90): < 90 ms

q Nominal supply voltage: 13.5 V

q Position sensor supply voltage: 5 V

q Maximum flow: 245 kg/h at dP20 hPa

q Internal leakage: ≤ 3 kg/h at dP 600 hPa

q Max. differential pressure over flap: 300 kPa

q Exhaust gas temperature: 100 up to 200°C

88 89

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S & A Actuators

Linear Purge Valve (LPV)

q Canister regeneration with a linear proportional solenoidq Very low operating noise due to constant current inputq Fast response for incremental flow control at all operating conditionsq Excellent low end flow control to prevent unwanted surges of fuel vapor


q Typical flow 70 SLPM at 57 kPa

q Operating voltage 14 V

q Coil resistance 14.0 Ohms

q Maximum current 500 mA

q Control circuit Constant current at 150 up to 200 Hz

q Weight 200 g

General Purpose Actuator (GPA)

q Continuous adjustment of external application using rotating output shaft q Ideal for use in turbocharger applicationsq Option: Default Positionq Permanent feedback signal (non-contacting)


q Max. external load without return function 86 Ncm

q Response time less than 100 ms at 140°C

q Operation temperature – 40 up to +140°C

90 91

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S & A Actuators

Pump (SCP) Smart Coolant Pump

q Precise engine temperature control through variation of coolant volume flowq Operation independent from engine for fuel economy, comfort, and advanced propulsion applications


q Electronically commutated BLDC motor

q Integrated electronics in thick film technology

q Wet running permanent magnet rotor

q Volume flow 9000 l /h

q Differential pressure 800 hPa

q Hydraulic power 200 W

q Supply current at Pmax 32 A

q Coolant temperature range – 40 up to +128°C

Pump (EWP) Electrical Water Pump

q Variable small coolant pumps for engine and power electronics cooling as well as cooling of the turbocharged airq Use of energy meeting the demands q Operation independent from main cooling circuitq Operation independent from combustion engine operation


q Electronically commutated BLDC motor; wet running rotor

q Modular design concept with or without integrated speed control electronics

q Volume flow 700 up to 1800 l /h

q Differential pressure 500 up to 900 hPa

q Hydraulic power 10 up to 45 W

q Coolant temperature range – 40 up to +128°C

92 93

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S & A Actuators

Variable Lift ControlActuator

q Continuous positioning of eccentric shaftq Adjusts valve liftq High dynamics (low inertia)q Closed loop control via integrated position sensorq EC motor mounted in cylinder head (small package)


q EC motor M42

q Diameter 42.6 mm

q Length 70.0 mm w/o connector

q Weight 567 g

q Max. EC motor power 480 W

q Stall torque 70 Ncm with current limited by the ECU


Brushless DC-Motor

Pump (TOP) Transmission Oil Pump

q Automatic or Double Clutch Transmissions with Full Hybrid or Start-Stop Systems q Continental as system supplier for all three components q E-Motor and electronics from one sourceq Already serial production history with integration of motor, pump, and electronics in one unit


q Electronically commutated BLDC motor with or without sensor

q Electric power: ~ 150 W up to 700 W

q Electronics ambient temperature capabilities: up to 140°C

q Available pump types depending on requirements – Vane-type – G-Rotor

94 95

Door Handle Sensor

q Easy to integrate into the door handleq Low power consumption (<100 µA for double zone sensor)q Reduced false detection thanks to adaptation of environment conditions (rain, fog, snow...)


q Capacitive sensor for Keyless Entry System

q Detection distance 0 up to 40 mm

q Response time < 5 ms up to 30 ms

q Optional: – Capacitive sensor for door locking – Mechanical switch for door locking – Movement sensor – LED for ground/pocket illumination – LF antenna integration – NFC reader (access with mobile phone)

S&

A

S & A Sensors

Fluid LevelOil Level Switch

q Low oil level detectionq Different connectors possibleq Simple on/off output


q Measuring principle: magnetic reed switch

q Different switch heights possible

q Normally on (switch closed)

q Tolerance: ± 1 mm

96 97

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A

S & A Sensors

Fluid Level SensorCapacitive QLT

q Overfill and low level indication q Absolute measurement of oil level in static and dynamic conditions. Replacement of oil dipstickq Stand-alone sensor with integrated electronics (“active”)q Oil quality information (permittivity)q Extension of the oil change intervals


q Measuring principle capacitive

q Measuring range 40 up to 120 mm

q Accuracy ± 2 mm

q First measurement available in 1.4 sec after key-on

q Measuring interval ~ 1 sec.

q Permittivity measuring range (quality) 1 up to 6 Typical value for engine oils 2 up to 3

q Temp. measuring range – 40 up to + 160°C

QLT =QualityLevelTemperature

q Replacement of oil dipstickq Detection of low level and overfillq Absolute measurement of oil level in static and dynamic conditionsq Stand-alone sensor with integrated electronics (“active”) and ASICq Low power consumptionq Temperature measurement optional


q Measuring principle ultrasonic echo

q Measuring range 18 mm up to 120 mm

q Accuracy ± 2 mm

q First measurement available 0.4 sec after key-on

q Power supply 12 V/10 mA typical

q Measuring interval ~ 1 sec.

q Operating temperature – Level – 10 up to + 150°C – Temperature – 40 up to + 150°C

Fluid Level SensorUltrasonic

98 99

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S & A Sensors

Fluid Level SensorPassive Electrothermic

q Overfill and low level indication q Absolute measurement of oil level in static and dynamic conditionsq Replacement of oil dipstickq Different mounting positionsq Temperature measurement optional


q Measuring principle thermoresistive heated wire

q Measuring range 110 mm betw. min. & max.

q Accuracy approx. ± 3 mm

q First measurement available 0.6 s after key-on

q Measuring interval > 5 sec

q Current consumption max. ~200 ± 1 mA (pulse mode)

q Operating temperature – 40 up to + 160°C

q Temp. measurement optional with NTC (± 2°C)

Fluid QualityFlex Fuel Sensor

q In line sensor mounted between fuel tank and engineq Ethanol content determined prior to combustion q Meets OBD II functional requirementsq Allows usage of saddle tanks on flex fuel vehicles q Reduces the likelihood of engine stall for safer car operation q Active temperature and conductivity compensation q Simple compact design, proven safe and reliable q Various connector interfaces available


q Measures Ethanol content of Ethanol /Gasoline mix 0 up to 100%

q Accuracy ± 5% on Ethanol

q Frequency output based on percent Ethanol


q Supply voltage 9 up to 18 V

q Maximum flow 400 l /h (80 g/s)

100 101

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S & A Sensors

Fluid QualityFlex Fuel Sensor

q Next generation in line Flex Fuel Sensor mounted anywhere between the fuel tank and engineq Design is smaller and more compact for ease of packagingq Assembly capable of various mounting methodsq Accuracy equivalent or better than current designq Qualified for higher vibration profiles (engine mount)q Allows for emission and cold start improvementsq Self diagnostics capability


q Measures Ethanol content of Ethanol /Gasoline mix 0 up to 100%

q Frequency output based on percent Ethanol



q Maximum flow 400 l /h (80 g/s)

High Integrated

Fluid QualityFuel Quality Sensor

q Real time optimization and protection of engine and exhaust gas aftertreatment systemq Reduction of pollutant emission and fuel economyq Improvement of drivability (e.g. knocking, cold start)q Fuel quality data logger

Technical Information (A-samples)

q Optical principle (infrared dispersive spectroscopy)

q Measurement location in fuel line (in tank possible)

q Pressure range 10 bar max

q Temperature range – 40 up to + 85°C

q Output signal CAN

q Response time 30 s (for complete fuel parameter set)

q Diesel parameters: cetane number, bio concentration, density, heating value, aromatics, sulfur content classification, misfuel warning

q Gasoline parameters: RON, density, oxygen (ethanol) content, RVP, distillation curve

102 103

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S & A Sensors

In-CylinderPressure Sensor

q Stand-alone sensor allowing closed-loop combustion control for gasoline and diesel enginesq Easy to integrate q Reduces emissions q Increases engine powerq Reduces fuel consumptionq Simple and robust solution


q Accuracy: 3.5%

q Various connector designs

q Active sensor

q Small size sensor: M8 thread

Hydrocarbon Sensor

q Detects concentration of a 2 gas compound mix up to 100%q Applications possible: CNG, canister purge, crankcase ventilation, etc.q Optimized regeneration of charcoal canisterq Reduce system costs e.g. by avoiding usage of high pressure fuel tanksq Optimized Engine-Management: can help to optimize injection time and injected fuel volume depending on the purged HC gas from purge canister and/or crankshaft housing


q Ultrasonic sensing technology

q Operation temperature – 40 up to + 80°C

q Measuring range 0% up to 100% HC concentration

q Response time ~50 ms

q Accuracy 2 up to 3% (Butane)

104 105

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S & A Sensors

Knock Sensor –Wide Band

q Used to optimize ignition timing for maximum efficiencyq High sensitivityq Compact design, nested bolt possibleq Increases engine powerq Decreases fuel consumption


q Acceleration sensor based on piezo ceramic technology with a range of: 0 up to 400 g

q Frequency range: 3 up to 25 kHz

q Possible integration of discharge resistor

q Integrated connector or cable version

q Various connector designs

Mass Airflow Sensor

q High flow measurement accuracy and exceptional signal stabilityq Integral protection against water and contaminationq Customer specific programmable output characteristicq Excellent performance with intake airflow pulsationq Low power consumption and fast start-up timeq Flow range adaptable for secondary airflow (SAF) and fuel cell applications


q Sensing technology Hot-film bi-directional MEMS

q Flow range 5 up to 800 kg/h (62 mm tube)

q New-part tolerance 1.5%

q Supply voltage 5 V ± 0.5 V

q Supply current 10 mA maximum

q Output signal Frequency or SENT digital

q Integrated intake air temperature sensor optional

1 In-Tube MAF Sensor2 Plug-In MAF Sensor

21

106 107

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S & A Sensors

Natural Vacuum LeakDetection (NVLD II)

q With, or without Integrated Electronic (NVLD II smart)q Diagnostic performed after key offq Stand-alone or canister mounted versionsq Temperature sensingq Pressure switch sensingq Timer function


q Vacuum sensing switch with – 2.5 ± 0.3 mbar calibration

q Damping feature to avoid noise

q Weight approx. 100 g

q Bit serial communication with ECU

q Average current consumption < 50 µA

q High In Use Monitor Performance Ratio (IUMPR > 80%)

Position Sensor –Linear Contactless

q Sensor is smaller than strokeq “Through wall” measurement, high airgapq Applications: Neutral gear (X-Y, Neutral + Rear, or detent pin integrated), clutch cylinder, transmission fork, Park Lock, PRNDL, pneumatic valve covers...


q Overall accuracy min. ± 2% (incl. ageing, temperature, airgap)

q Target Magnet (compatible with through Al wall sensing)

q Measurement linear up to 60 mm

q Airgap up to 11 mm

q Operating temp. range – 40 up to +150°C

q Operating voltage 5 V ± 0.5 V

q Output signal Analog, PWM, SPI or SENT

q X-Y measurement possible

Hall EffectTechnology

108 109

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S & A Sensors

Position Sensor – Linear Contactless

q Easily configurable for redundancyq Target is non-magnetic (Al, Fe, ...), low costq No hysteresis, no pollution through iron particlesq Immune versus low frequency magnetic field q Applications: – Transmission position sensors: PRNDL, Clutch Master Cylinder, Gear, DCT fork – Engine position sensors: thermal management valve, EGR, Turbo


q Measuring range 10 mm to 60 mm

q Overall accuracy ± 2% (incl. ageing, temperature, airgap)

q Airgap 0.5 up to 3 mm

q Linearity < ± 1% full scale


q Max. drift over temperature < ± 1%

q Output signal Analog, PWM or SENT

InductiveTechnology

Position Sensor – Rotary Contactless

q Easily configurable for redundancyq Target is non-magnetic (Al, Fe, ...), low costq No hysteresis, no pollution through iron particlesq Immune versus low frequency magnetic field q Applications: transmission range, transfer case engine management stand alone sensors (VVL, swirl, portflap...) and actuator covers (VVL, ACV, ETC, EGR), thermal management


q Measuring range up to 360°

q Overall accuracy ± 2% (incl. ageing, temperature, airgap)

q Airgap 0.5 up to 3 mm

q Linearity < ± 1% full scale


q Max. drift over temperature < ± 1%

q Output signal Analog, PWM or SENT

InductiveTechnology

110 111

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S & A Sensors

Position Sensor –Rotary Contactless

q Sensor only sensitive to magnetic field orientation (not strength)q Sensor is immune to external magnetic field due to the target wheel /sensor configurationq Contactless sensing no mechanical wear (improved reliability and durability) q Applications: stand alone and actuator coupled – VVL, ACV, ETC, EGR


q High accuracy of MR technology (± 1°)

q Redundant/self diagnostics

q Analog or SPI digital output

q High accuracy 0.022° resolution

q Measuring range 0 up to 180°


q Hysteresis < 0.1°

Magneto-ResistiveTechnology

Pressure Sensor –Fuel High Pressure

q Direct measurement of pressureq Flexible calibration of transfer functionsq Precision programmable clip levelsq Internal and output diagnostic capabilityq Large measurement rangeq High accuracy and temperature stabilityq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure range 0 up to 2200 bar

q Accuracy 1% full scale (10 up to 85°C)



q Supply current at 5 V 10 mA maximum

q Load resistance > 4.7 kW

q Response time < 1 ms

q Output signal Analog or SENT

GDI and DDI

112 113

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S & A Sensors

Pressure Sensor –Low Pressure Absolute

q Direct measurement of vacuum q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic responseq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure Range 10 up to 120 kPa







Brake Booster Absolute (BBA)


q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure Range 7 up to 500 kPa (for BAP)

q Pressure Range 20 up to 300 kPa (for MAP and Turbo MAP)







MAP, TMAP, BAP

114 115

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S & A Sensors


q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic responseq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure Range 50 up to 150 kPa (for SAA)







Secondary Air Absolute (SAA)

Pressure Sensor – Low Pressure Differential

q Direct measurement of vacuum q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic responseq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure Range –105 up to 40 kPa (gauge)







Brake Booster Gauge

116 117

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A

S & A Sensors

q Direct measurement of pressureq Flexible calibration of transfer functionsq Precision programmable clip levelsq Internal and output diagnostic capabilityq High accuracy and temperature stabilityq Excellent dynamic responseq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Adjustable characteristic via electronic calibration

q Pressure range 0 up to 10 kPa



q Transfer function linear, ratiometric

q Accuracy over full-scale 3% full span (10 up to 85°C)



Filter ControlGauge


ManifoldGauge

q Direct measurement of pressureq Flexible calibration of transfer functionsq Precision programmable clip levelsq Internal and output diagnostic capabilityq High accuracy and temperature stabilityq Excellent dynamic responseq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure range –105 up to 40 kPa (gauge)

q Accuracy 1% full scale (10°C up to 85°C)






118 119

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S & A Sensors

q Differential measurement of the exhaust gas pressure across the diesel particle filterq Direct measurement of pressureq Flexible calibration of transfer functionsq Precision programmable clip levelsq Internal and output diagnostic capabilityq Large measurement rangeq High accuracy and temperature stability


q Pressure range 0 up to 100 kPa P1 (downstream port) 0 up to 50 kPa P2 (upstream port) 0 up to 150 kPa

q Operating voltage Programmable (0.200 up to 4.800 V)

q Accuracy 0.8% FSS (0 up to 70°C)


q Response Time <1 ms


Particulate Filter Differential

q Direct measurement of pressureq Flexible calibration of transfer functionsq Precision programmable clip levelsq Internal and output diagnostic capabilityq High accuracy and temperature stabilityq Fulfills toughest EMC requirementsq Flexible housing, connector, and mounting designs


q Pressure range 0 up to 125 kPa






q Response time < 2 ms



Particulate Filter Gauge

120 121

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A

S & A Sensors

Smart NOx Sensor

Calibrated High Accuracy NOx Sensorq Sensor detects NOx and Oxygen concentration up-/downstream of exhaust after treatment components compliant with OBD legislationq Self diagnosis capability regarding signal degradation and shortcut /open wireq All electronics including heater control and drivers integrated in the sensorq Standardized electronic interface with CAN-Bus


q Measuring principle ZrO2-based multilayer sensor with integrated heater and 3 oxygen pumps

q Triple output signal NOx, binary λ, linear λ or O2 concentration

q Supply voltage 12 V or 24 V

q Data link CAN 2.0 or SAE-J-1939

q Operating gas temp. 100 up to 800°C

Smart Particulate Matter (PM) Sensor

Calibrated “Stand-Alone“ PM Sensorq Detects soot particle concentration downstream of Diesel particle filter compliant w. OBD legislationq Supports “Real time” measurement of particle concentrationq Shortcut and open wire self diagnosis capabilityq All electronics including heater control and drivers integrated in the sensorq Standardized electronic interface with CAN-Bus


q Measuring principle Al2O3-based sensor with resistive measuring electrode

q Output signals PM in mg/m3, regeneration frequency

q Supply voltage 12 V or 24 V

q Measuring range 0 up to 25 mg/m3

q Operating gas temp. 100 up to 400°C

122 123

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S & A Sensors

Temperature Sensor –Coolant /Fuel /Oil

q Clip or screw-in design q Wide range of applicationsq High accuracyq Short response timeq Long-term stabilityq Certified qualityq High worldwide volume production


q Oil, water, fuel, temperature measurement – Engine coolant – 40 up to +150°C – Engine oil – 40 up to +150°C – Fuel – 40 up to +140°C

q Accuracy ±1°C (at 0°C)

q Response time up to 3s

Temperature Sensor –High Temperature

q Active sensor price in the range of a passiveq High accuracy (Thermocouple principle)q Price benefit for customer at ECU-system q Lower signal ageing over lifetimeq Fast response, high robustness and higher resolution of temperature signal (12 bit)q Smaller package of sensing probe is possible


q Output signal: LIN, PWM, CAN, SENT, 5 V analog ratio

q Response time: 6 s at 10 m/s (4 s at 20 m/s gas)

q Sensing temperature – 40 up to +1200°C

q Working temp. electronics – 40 up to +125°C (+140°C optional)

q Accuracy low temp. (< 500°C) ± 5°C

q Accuracy high temp. (> 500°C) ± 10°C


124 125

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S & A Sensors

Temperature Sensor –Intake Air

q Clip or screw designq Wide range of applicationsq High resolution q Short response timeq Long-term stability q Certified qualityq Open or closed design


q Intake air temperature measurement

q Intake air temperature – 40 up to +150°C

q Diesel and gasoline application

q Response time up to 4 s

Temperature Sensor –EGR

q Measures intake air temperature with high EGR ratesq Optimized design for high temperatures (up to 400°C) in case of connector versionq Very robust q Certified qualityq No chemical and soot impact on Ptq Cable version in development



q Short response time up to 7 s

Temperature Sensor –Outside Air

126 127

q Splash-proof plastic housingq Easy snap-in installationq Price benefi tq High accuracyq Long-term stabilityq Certifi ed qualityq High worldwide volume production


q Outside air temperature measurement

q Outside air temperature: – 40 up to +120°C

q Different NTC curves possible

q Average ± 1°C over temperature range

S&

A

S & A Sensors

128 129

FS

Fuel SupplyFuel Supply – FS

FS

130 131

Modular Fuel Supply Unit

q Various customer specific designs possible based on modular conceptq Flange geometry can be adapted to customer requirementsq Integrated tank managementq Variants: constant flow or flow controlled


q Different fuel pumps (Ø 38 mm/43 mm) with EC (electronically commutated) or DC (direct current) motor

q Integrated “lifetime” fuel filter

q Integrated pressure regulator

q MAPPS (MAgnetic Passive Position Sensor) fuel level sensor

FS

Fuel Supply – FS

NewGeneration

Modular Fuel Level Sensor with MAPPS

q Redundant contactsq Best EMC because of passive systemq Longer life time (> 10 million cycles) because of wear-resistant measurement systemq Hermetically sealed contacts assure perfect protection against contamination of all types of fuel


q Measuring range angle up to 86.7°

q Operating current 1 up to 20 mA

q Resolution 1.7° =~ 2%

q Max. total error of resistor ± 1%

q Interface 2-wire resistance signal, 50 up to 1000 Ω linear voltage at ADC

q Operating temperature – 40°C up to + 125°C

q Dynamic strength 200 m/s² (0 Hz...1 kHz)

MAPPS (MAgnetic Passive Position Sensor)

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Code Description forNames of Fuel Pumps

FS

Fuel Supply – FS

EC Fuel Pumps(43 mm)

q In-tank fuel pumps with electronically commutated (EC) motorq Twin channel turbine pump stage (Gasoline)q Gerotor pump stage (Diesel)q Emission reductionq Essential pump control electronics offer demand controlled operation

Tech. Information G43D/EC D43Gp/EC

q Working point example:

– Pressure, KPa 500 500

– Flow, l /h typ. 245 245

– Speed, 1/min. 7000 5800

– Power, W typ. 115 90

q Media Premium, Un- Diesel/RME leaded, Tropical, Flex Fuel

q Diameter 43 mm 43 mm

1 D43Gp/EC

2 G43D/EC 2

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Fuel Supply Electronics Modular FunctionCarrier (MFC)

q Enhanced fuel pump lifetime in comparison to systems without demand controlq Reduced consumption of electric energyq Reduced noise and emission level


q Integrated in the flange of the fuel supply unit or stand-alone device

q Enables an EC (electronically commutated) or DC (direct current) fuel pump to provide only the amount of fuel to the engine which is currently demanded

q Processing of fuel level sensor signals (optional)

q Integrated theft protection (optional)

q Suitable for almost all tank designsq Integrated carbon canister (optional)q Reduction of permeation


q Operating ventilation

q Refueling ventilation (optional)

q Roll over function

q Retaining vapor with integrated carbon canister (optional) F

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Emission Technology – EMITEC

EmissionTechnology

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EMITECEmission Technology


Emitec: A brief company profile

Emitec Gesellschaft für Emissionstechnologie mbH, a joint venture between international automotive sup-pliers Continental and GKN Driveline, was founded in 1986. Today, the company is a world leader on the metal substrate market for exhaust gas catalysts and metallic diesel particulate filters for vehicles and mobile machinery. Complete SCR systems round off this product range. Since its foundation Emitec has sold more than 100 million metal substrates of the highest quality with excellent operating report: zero field failures. With its own development and test centre, Emitec has been partner of the automotive and engine industry regarding product and system developments for many years.

The company employs around 1000 people in Lohmar and Eisenach, Germany, in Longeville-lès-Saint-Avold, France, at the Fountain Inn plant in South Carolina,

USA, at the plant in Pune, India and at several application engineering offices around the world. Devel-opment centres are based in Lohmar, Eisenach and Denmark.

Emitec’s most important markets are in Europe, North America and Asia. The company has subsid- iaries in China, Japan and Korea.

The company’s customers include the major car, truck and motorcycle manufacturers from across the world as well as in the non-road sector producers of tractors, agricultural machinery, construction equip-ment, ships and diesel locomotives. Emitec owns over 1,800 patents worldwide, a fact that reflects the company’s innovative strength.

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METALIT® (3-Way-Cat) NOX-Adsorber

NOX-adsorption catalysts: Technology for lean-mixture Otto-DI and Diesel engines


q Capacity and regeneration are important for overall efficiency and fuel economy

q High cell densities help to improve mass transfer and therefore conversion efficiency

q Enhanced functionality due to included NOX Sensor

q Additional storage volume after the sensor increases safety margin

Leading metallic substrate technology


q Low heat capacity for quick light-off

q Foil thicknesses from 20 up to 110 µm

q Structured foils for enhanced efficiency are possible

q Cell densities 50 up to 1600 cpsi

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Pre Turbo METALITTM Compact Cat ®

Excellent Cold Start Performance


q Use of higher exhaust gas temperature

q Increases HC/CO efficiency (turbulent flow)

q Reduces the needed Diesel Oxidation Catalyst volume

q Significant system cost reduction possible (Preturbo Catalyst + Diesel Oxidation Catalyst)

Compact design for close coupled applications with optimized heat management


q Compact design for close coupled applications especially for Diesel applications

q Mounted directly to the turbocharger for fast light-OFF

q High efficiency due to optimized heat management

q Potential for cost savings by volume reduction

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PM-METALIT® SCRi®-System

Catalyst system with integrated particle reduction and turbulent substrates


q Future filter strategies have to be adapted to changing particulate sizes

q Continuously working particle system without regeneration

q Above-average elimination in smallest particles

q High performance reduction catalyst turbulence generating LS/PE-Design with optimized coating allows volume reduction

Partial – flow deep bed filter for ultrafine particulate matter


q Particulates are deviated in the shovel and deposed in the fleece layer

q In conjunction with NO2 from the oxidation catalyst continuous particle reduction

q Side-flow system guarantees discruption-free engine operation through deep-bed filtration

q EU 4/5 without urea

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LS-Design® PE-DesignTM

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Turbulent Catalyst


Longitudinal Structure Design

q Reduction of material /weight

q Improvement of cold start performance

q Increased mass transfer

q Catalyst efficiency

Turbulent Catalyst


Perforated Metal Foil Design

q Lower backpressure

q Faster light off

q Improved turbulent mass transfer


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Selective CatalyticReduction – SCR


Tank-integrated Dosing System


Urea Injection

q Compact design

q Stainless steel

q Central heating

q Pressure release instead of system purging

Air Assisted Dosing System


Urea Injection

q Air assisted dosing system

q Capacity up to 8 l/h

q Simple one-hole nozzle

q OEM version

q Standalone system for retrofi t


Reduction – SCR

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AirlessDosing System


Urea Injection

q Airless dosing system

q Capacity up to 8 l /h

q Nozzle air /water cooled

q OEM version

DigitalDosing System


Urea Injection

q Dosing pump up to 960 l /h

q Both airless/air assisted version

q Full range of nozzles

q High precision at both low and high fl ow




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The information provided in this brochure con-tains only general descriptions or performance characteristics, which do not always apply as described in case of actual use or which may change as a result of further development of the products. This information is merely a technical description of the product. This information is not meant or intended to be a special guarantee for a particular quality or particular durability. An obligation to provide the respective characte-ristics shall only exist if expressly agreed in the terms of contract. We reserve the right to make changes in availability as well as technical chan-ges without prior notice.

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Continental Automotive GmbHSiemensstrasse 12 93055 Regensburg GermanyPhone +49 941 790-0Fax +49 941 790-14www.continental-corporation.com

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