Powertrain Solutions Technical Information Powertrain Solutions 2 3 Powertrain

Home , Common rail, Electronic control unit

Powertrain Solutions Technical Information Powertrain Solutions 2 3 Powertrain. Content Energy for Your Drive.

Powertrain Solutions Combustion Electrification Systems Gasoline

Connectivity After-treatment Combustion Systems Diesel Efficiency

Vehicle Applications

Passenger Cars Off-Highway Safe, eco-friendly driving with your own vehicle – ar- rive relaxed at your destination. Few things fascinate Trucks and Buses Recreation people around the world like the issue of mobility. At the same time, mobility today is undergoing funda- 2-Wheelers Marine mental changes. We are one of the leading developers and manufac- 12 System Overviews turers of solutions for efficient combustion engines and after all pioneers in the field of efficient system 12 Diesel Injection and After-treatment System technology and economical vehicle integration in 14 Gasoline Direct Injection System electric vehicles using electric power as an additional 16 Gasoline Port Fuel Injection System energy source. 18 High Voltage Electrification 20 48 Volt Electrification Both fields of innovation ultimately pursue the same goal: Lowering CO2 and emissions. This is the goal pursued by the Powertrain division in the five solution areas electrification, connected energy management, combustion, exhaust after-treatment and drivetrain efficiency. Powertrain Solutions 4 5 Content

22 Electrification Solutions 46 Electrification Solutions Hybrid & Electric Vehicle Hybrid & Electric Vehicle 24 HV Axle Drive with Integrated Inverter 46 12 V Dual Battery Management System 25 HV Power Electronics, Inverter + DC/DC Converter 47 12 V Power Net System 26 HV Inverter Sensors & Actuators 27 HV DC/DC Converter 48 Brushless DC Motor for Brake Applications 28 HV Battery Management System (BMS) 29 HV Battery Junction Box (BJB) 50 Connectivity Solutions Engine Systems Sensors & Actuators 30 HV Battery On-Board Charger 52 Door Handle Sensor 31 HV Battery Wireless Power Transfer System 53 Door Handle Sensor with NFC Reader Hybrid & Electric Vehicle 54 Door Handle Sensor BLE 32 HV Axle Drive and Charging 55 Easy Trunk Access Sensor 33 HV Boost Converter Engine Systems 56 Combustion Solutions 34 Vehicle Control Unit 35 48 V eCompressor Engine Systems Hybrid & Electric Vehicle 58 Customized Fuel Delivery Module 36 48 V Air Cooled Belt Starter Generator (BSG) 59 Diesel Dosing Injector 37 48 V Liquid Cooled Belt Starter Generator (BSG) 60 Diesel Fuel Rail 38 48 V DC/DC Converter 61 Diesel High Pressure Pump DHP1.1 39 48 V Battery Management System 62 Diesel High Pressure Pump DHP2 Transmission 63 Diesel High Pressure Pump DHP3 40 Control Unit for Double Clutch Transmission 64 Diesel Piezo Common Rail Injector PCRs5 41 Control Unit for Stepped Automatic Transmission 65 Diesel Pressure Decay Valve PDV 1-25 Sensors & Actuators 66 ECU Bi-Fuel Ready-to-Use EasyU 42 Electrical Water Pump 67 ECU Diesel Heavy Duty Engines 43 Temperature Sensor – Coolant 68 Piezo Common Rail 44 Coolant Flow Control Valve – Non-Smart 69 ECU Diesel Platform for Commercial Vehicles 45 Coolant Flow Control Valve – Smart 70 ECU Gasoline Port Fuel Injection 71 ECU Gasoline Port Fuel Injection Ready-to-Use EasyU Powertrain Solutions 6 7 Content

72 Combustion Solutions 99 Combustion Solutions 72 ECU Gasoline SDI and TCU 99 Digital Linear Actuator Compact Size – Gen VII 73 ECU Gasoline SDI Ready-to-Use EasyU 100 Digital Linear Actuator Standard Size – Gen I 74 ECU Gasoline Solenoid Direct Injection 101 Digital Linear Actuator Standard Size – Gen II 75 ECU M3B (Air Module) 102 Digital Linear Actuator Standard Size – Gen V 76 ECU M3C 103 Electrical Compressor Bypass Valve 77 ECU M4D Ride By Wire 104 Electrical Exhaust Gas Recirculation Valve 78 ECU M4L/XE Air Module 105 Electronic Throttle Control 11.2 – Economy Line 79 EMS3 Engine Management System Platform 106 Electronic Throttle Control ETC 12 – Modular Perform. 80 Gasoline Deka 10 Port Fuel Injector 107 Electronic Throttle Control 13 – Economy Line 81 Gasoline Deka 7/9 Port Fuel Injector 108 Electrical Wastegate Actuator 82 Gasoline DI XL3.1 Solenoid Injector 109 Exhaust Control Valve – High Pressure 83 Gasoline DI XL5 Solenoid Injector 110 Exhaust Control Valve – Linear 84 Gasoline Fuel Rail Assembly 111 Exhaust Control Valve – Low Pressure 85 Gasoline High Pressure Pump GHP2.5 DI/PFI 112 Fluid Sensor – Flex Fuel Ethanol 86 Gasoline High Pressure Pump GHP2.5 113 Fluid Sensor – Oil Level Passive Electrothermic 87 Gasoline Turbocharger with Aluminum Turbine 114 Fluid Sensor – Oil Level Switch Housing 115 Fluid Sensor – Oil Level Ultrasonic 88 Gasoline Turbocharger with Steel Turbine Housing 116 In Cylinder Pressure Sensor 89 Gasoline Turbocharger with VRAAX™ Turbine 117 Knock Sensor M6 Small Design Technology 118 Knock Sensor M8 Standard Design 90 Ignition Coil 119 Latching Valve 91 Oxygen Sensor 120 Linear Purge Valve Sensors & Actuators 121 Natural Vacuum Leak Detection (NVLD III) 92 Active Purge Pump 122 Pressure Sensor – Brake Booster Absolute 93 Air Control Valve Economy Line S11.1 123 Pressure Sensor – Brake Booster Gauge 94 Air Control Valve – Performance Line S8.6 124 Pressure Sensor – Filter Control Gauge 95 Air Control Valve 12 – Modular Performance 125 Pressure Sensor – Filter Control Gauge – 96 Air Control Valve 12 – Modular Performance Air Filter Pressure 97 Brushless DC Drives High Efficiency 126 Pressure Sensor – Filter Control Gauge – 98 Canister Purge Solenoid CPS6 Diesel Crankcase Pressure Powertrain Solutions 8 9 Content

127 Combustion Solutions 155 Exhaust After-treatment Solutions 127 Pressure Sensor – Filter Control Gauge – 155 EMICAT® Electrically Heated Catalyst Gasoline Crankcase Pressure 156 Three-Way Catalyst (TWC) 128 Pressure Sensor – Fuel Vapor Gauge 157 Diesel Oxidation Catalyst (DOC) 129 Pressure Sensor – High Pressure Diesel 158 SCR Catalyst 130 Pressure Sensor – High Pressure Gasoline 159 SCR Light-Off Catalyst 131 Pressure Sensor – Manifold Absolute – MAP TMAP BAP 160 Exhaust After-treatment System for Two-Wheeler 132 Pressure Sensor – Manifold Absolute and Temperature 161 Close-Coupled After-treatment System Gasoline 133 Pressure Sensor – Manifold Gauge 162 Close-Coupled After-treatment System 134 Temperature Sensor – High Single Light-Duty (LDD) 135 Temperature Sensor – Coolant / Fuel / Oil 163 Compact Catalyst 136 Turbo Purge Valve 164 Compact SCR EHC System Light Duty (LDD) 137 Variable Compression Ratio (VCR) Actuator 165 Sensor Catalyst 138 Variable Turbine Geometry Actuator 166 Close-Coupled After-treatment System Heavy-Duty (HDD) 140 Exhaust After-treatment Solutions 167 Close-Coupled Oxidation Catalyst Heavy-Duty (HDD) 168 Universal Decomposition Pipe (UDP) Engine Systems 169 Ring-Shape DOC for Advanced Compact SCR 142 After-treatment Control Module 170 Ring Catalyst 143 Air-Cooled SCR Injector 171 Ring-Shape SCR EHC System 144 Liquid-Cooled SCR Injector 172 Particulate Matter Filter PM-METALIT® 145 Urea Dosing Control Unit 173 Exhaust Gas Recirculation Filter Fuel & Exhaust Management 174 Metallic Gasoline Particle Filter 146 CS-Design (Crossversal Structure) 175 Air-Assisted Urea Dosing Unit UDA 147 LS-Design® (Longitudinal Structure) 176 Tank-Integrated SCR Urea Extraction Unit Gen 4 148 LS-Design® and PE-Design® 177 Tank-Integrated SCR Urea Extraction Unit Gen III 149 MX-Design® (Mixing Structure) Sensors & Actuators 150 PE-Design® (Perforated Structure) 178 Electrostatic Particulate Matter Sensor 151 TS-Design®(Transversal Structure) 179 Fluid Sensor – Urea Concentration and Level 152 Straight Channel METALIT® (Standard Structure) 180 Mass Airflow Sensor – FMT MAF SENT 153 Thin Wall and Lightweight Catalyst 181 Mass Airflow Sensor – FMT MAF+HPT SENT 154 Controller for Electrically Heated Catalyst (EMICAT®) Powertrain Solutions 10 11 Content

182 Exhaust After-treatment Solutions 208 Drivetrain Efficiency Solutions 182 Mass Airflow Sensor – MT MAF 208 Control Unit for Double Clutch Transmission 183 Pressure Sensor – Particle Filter/EGR Differential 209 Control Unit for Double Clutch Transmission 184 Pressure Sensor – Particle Filter Gauge (Single Port) 210 Control Unit for Double Clutch Transmission 185 Pressure Sensor – Secondary Air Absolute 211 Control Unit for Double Clutch Transmission 186 Smart NOX Sensor – Gen 4.0A 212 Control Unit for Double Clutch Transmission 187 Smart NOX Sensor – Gen 4.0P 213 Control Unit for Double Clutch Transmission 188 Temperature Sensor – EGR 214 Control Unit for Double Clutch Transmission 189 Temperature Sensor – High Multiple 215 Control Unit for Double Clutch Transmission 216 Control Unit for Automatic Transmission 190 Drivetrain Efficiency Solutions 217 Control Unit for Stepped Automatic Transmission 218 Control Unit for Stepped Automatic Transmission Fuel & Exhaust Management 219 Control Unit for Stepped Automatic Transmission 192 Electric Fuel Pump – EC 220 Control Unit for Stepped Automatic Transmission 193 Electric Fuel Pump – DC 221 Control Unit for Continuously Variable Transmission 194 Fuel Delivery Module for Entry Level Vehicles 222 Universal Transmission Control Unit 195 Fuel Delivery Module for High-End Applications 223 Universal Transmission Control Unit Platform 196 Fuel Delivery Module for Standard Applications 224 Electronic Control Unit for Limited Slip Coupling 197 Fuel Level Sensor with an Open Contact System 225 Universal Control Unit for Powertrain Applications 198 Fuel Level Sensor with a Sealed Contact System 226 Transfer Case Actuator 199 Fuel Delivery Controller 227 Multi Position Linear Actuator 200 Tank Domain Controller 228 Direct Shift Module Sensors & Actuators 229 Sensorcluster for Wet Double Clutch Transmissions 201 Position Sensor – Linear Contactless 230 Smart Actuator Platform 202 Position Sensor – Rotary Contactless 231 Control Unit for Automated Manual Transmission (CV) 203 Position Sensor – Rotary or Linear Contactless 232 Control Unit for Double Clutch Transmission (CV) 204 Twin Drive Pump 233 Electronic Clutch Actuator (CV and Off-Highway) 205 Smart Position Sensor Cover Transmission

206 Control Unit for Double Clutch Transmission 207 Control Unit for Double Clutch Transmission System Overviews 12 13 Diesel Injection and After-treatment System

1 2 3 4 5 6 7 8 9 10 11 12 13 25 20 20 20 26 27 28 29 20 30 31 26 32

SCR/ DOC SDPF AOC 33 15 Tank Domain Controller 33 16 18 19 16 Temperature Sensor – Fuel 17 20 17 Diesel High Pressure Pump 18 Fuel Rail with High Pressure Sensor 21 14 15 and Pressure Decay Valve 22 19 In-Cylinder Pressure Sensor 1 Engine Control Unit 2 0 Temperature Sensor – High Single / Multiple 2 Mass Airflow Sensor 23 24 21 Temperature Sensor – Coolant / Oil 3 Pressure Sensor – EGR Differential 2 2 Fluid Sensor – Ultrasonic Oil Level 4 Exhaust Control Valve – Low Pressure 2 3 Crankshaft Position Sensor 5 Air Control Valve 2 4 Electrical Water Pump 6 Exhaust Control Valve – High Pressure 2 5 Variable Turbine Geometry Actuator 7 Temperature Sensor – EGR 2 6 SCR Injector 8 Exhaust Bypass Valve 2 7 Pressure Sensor – Particle Filter Differential 9 Pressure Sensor – Manifold Absolute with Temperature 2 8 Urea Concentration and Level Sensor 10 Camshaft Position Sensor 2 9 Tank-Integrated Urea Extraction and Pump Unit 11 EGR Catalyst 3 0 Exhaust Throttle Valve 12 Diesel Piezo Common Rail Injector 31 Urea Dosing Control Unit 13 EGR Filter 3 2 Electrostatic Particulate Matter Sensor 14 Fuel Delivery Module 3 3 Smart NOX Sensor System Overviews 14 15 Gasoline Direct Injection System

1 2 3 4 5 6 7 8 18 19 20

9 10

11 12

13 14 15 16 17 21 22 23 24 25 26 27 28 29 27

1 Engine Control Unit 16 Fuel High Pressure Sensor 2 Mass Airflow Sensor 17 Fuel Rail 3 Turbo Purge Valve / Canister Purge Solenoid 18 Pressure Sensor – Manifold Absolute and Temperature 4 Electrical Compressor Bypass Valve 19 Gasoline Direct Injection Solenoid Injector 5 Turbocharger 2 0 Active Camshaft Position Sensor 6 Pressure Sensor – Manifold Absolute 21 Fluid Sensor – Ultrasonic Oil Level 7 Electronic Throttle Control 22 Active Crankshaft Position Sensor 8 Exhaust Control Valve – High / Low Pressure (also with Direction Detection) 9 Pressure Sensor – EVAP 23 Knock Sensor 10 Active Purge Pump 24 Temperature Sensor – Coolant 11 Latching Valve 25 Electrical Water Pump 12 Tank Domain Controller 26 Three-Way Catalyst 13 Fuel Delivery Module 27 Temperature Sensor – High Single / Multiple 14 Fluid Sensor – Flex Fuel Ethanol Sensor 28 Gasoline Particle Filter 15 Gasoline High Pressure Pump 29 Pressure Sensor – Particle Filter Differential System Overviews 16 17 Gasoline Port Fuel Injection System

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17 18 19 17

1 Canister Purge Solenoid 11 Gasoline Port Fuel Injector 2 Fluid Sensor – Flex Fuel Ethanol Sensor 12 Active Crankshaft Position Sensor (also with 3 Electronic Throttle Control Direction Detection) 4 Fuel Rail 13 Knock Sensor 5 Pressure Regulator 14 Temperature Sensor – Coolant 6 Pressure Sensor – Manifold Absolute and Temperature 15 Active Camshaft Position Sensor 7 Natural Vacuum Leak Detection (NVLD III) 16 Three-Way Catalyst 8 Tank Domain Controller 17 Temperature Sensor – High Single / Multiple 9 Fuel Delivery Module 18 Gasoline Particle Filter 10 Engine Control Unit 19 Pressure Sensor – Particle Filter Differential System Overviews 18 19 High Voltage Electrification

1 2 3 4 5 8 9 10 11 3 12 5

Battery

Charging Infrastructure

12V boardnet

6 7 13 14 1 Ground Pad 11 Electrical Water Pump 2 Vehicle Pad 12 Axle Drive 3 Temperature Sensor – Coolant 13 DC-Booster 4 Electrical Water Pump 14 Inverter 5 Coolant Flow Control Valve 6 Onboard Charger 7 DC/DC Converter 8 Battery Management System 9 Vehicle Control Unit Electric circuit 10 Junction Box Coolant circuit System Overviews 20 21 48 Volt Electrification

1 2 3 4 5 6 7 8 9 10 11 12 13

12V boardnet

48V Battery

1 Engine Control Unit 10 48V Starter Generator (P2) 2 Vehicle Control Unit 11 Transmission Oil Pump 3 Coolant Flow Control Valve 12 Transmission Control Unit 4 48V Belt Starter Generator (P0) 13 Torque Transfer 5 48V eCompressor Device Control Unit 6 Electrical Water Pump 7 Temperature Sensor – Coolant 8 DC/DC Converter 9 Battery Management System Electric circuit Coolant circuit Electrification Solutions 22 23 Electrification Solutions

A Jack of All Trades Continental Powertrain is a pioneer in electrifying vehicle drives in both hybrid and electric vehicles. Electrification We are a leading system supplier of technology, from development to industrialization and series production applications. Here, we focus our innova- tions on achieving a healthy cost-benefit ratio, since only economical and practical solutions will find their way into series production. It is exactly this kind of tailor-made electrification that has made us a pioneer in mild hybridization with 48V Eco Drive technology: Providing a low cost hurdle in terms of integration, this system results in fuel savings of up to 21 percent in urban traffic. Another focus is on making smart use of the new opportunities that come along with electrification – including new forms of interaction. These include, for example, more electrically driven components and economical power-on-demand functions. Electricity is a jack of all trades in these kinds of applications. Hybrid Electric Vehicle 24 25 HV Axle Drive with HV Power Electronics Integrated Inverter Inverter + DC/DC Converter Electrification

Highly integrated electric drive system. Reduced efforts Drives electric machine in traction and generator mode. at customer for integration, sourcing, validation. Converts energy between HV battery and 12 V boardnet.

› Integration of motor, inverter, and reducer › Sintered power stage for maximum reliability › No connectors, no cables between motor and › Very high power density inverter, easier vehicle assembly Benefits Benefits › Inverter: Motor and generator mode, › Scalability through variable rotor/stator length DC/DC: Buck and boost mode › EV-series-proven technologies › For hybrid and electric vehicle applications › Modular design for standalone and integrated › Lower vehicle integration effort solutions

› Max. torque (machine): 310 Nm › Inverter performance: Up to 450 V/450 A peak › Gear ratio: 1:7.5 up to 1:10 › DC/DC: 3.6 kW peak / 3 kW cont. › Max. machine power: 140 kW up to 160 kW › AUTOSAR compliant SW architecture › Continuous power: 65 kW › Safety Level: Inverter ASIL C DC/DC ASIL C optional › High power variant with 600 Nm, 250 kW peak › High power density provides compact packaging Technical Information Technical Technical Information Technical Hybrid Electric Vehicle 26 27 HV Inverter HV DC/DC Converter Electrification

High power inverter for driving the electric machine in Ensures energy flow between the high voltage and the traction and generator mode. low voltage boardnet in hybrid and electric vehicles.

› Sintered power stage for maximum reliability › Precharge function from 0 V › Increased peak and cont. power for high power › AUTOSAR compliant SW architecture applications Benefits Benefits › Buck and boost mode for bi-directional energy flow › Motor and generator mode › Customizable for input voltages of 800 V and › For hybrid and electric vehicle applications output voltages of 48 V › For hybrid and electric applications › Inverter performance: Up to 460 V/ 600 A peak › AUTOSAR compliant SW architecture › DC/DC power scalable up to 3.6 kW › Output current one phase: 160 A at 14.5 V cont. › Safety Level: ASIL C › Output current two phase: 250 A at 14.5 V cont. › Nom. operating voltage range HV: 250 V up to 475 V › Nom. operating voltage range LV: 9 V up to 16 V

Technical Information Technical › Temperature range: –40°C up to +85°C

Technical Information Technical › Safety Level: ASIL B (D), ASIL C optional Hybrid Electric Vehicle 28 29 HV Battery Management HV Battery Junction Box System (BMS) (BJB) Electrification

Manages all functions of the high voltage Li-Ion battery Interfaces the battery cell stack with the vehicle applied to hybrid and electric vehicles. high voltage powertrain and the charging devices.

› Calculates state of charge and state of health › Localized HV interfaces and ease of servicability of battery cells › Customizable to various battery designs, packaging, › Controls internal and external actuators like and cooling concepts Benefits contactors, cooling pumps, etc. Benefits › High power applications including fast DC charging › Scalable design, compact size, and weight › Possibility to integrate others electronics › Modular structure including the Battery Manage- components (BMS / DC/DC) ment Controller and the Cell Supervising Circuit › Separate HV / high current interfaces to the vehicle › Monitoring of Li-Ion cells for 400 V/ 800 V systems (e.g. inverter, chargers, auxiliaries) › Integrated HV system isolation measurement › Contains switching and overcurrent protection › Scalable monitoring of cell temperatures components › Scalable contactor control and monitoring › Charging Power: Up to 350 kW › Multiple options for battery current measurement › Voltage Range: Up to 800 V › Integrated cell balancing Technical Information Technical

Technical Information Technical › AutoSAR compliant software Engine Systems 30 31 HV Battery HV Battery Wireless Power On-Board Charger Transfer System Electrification

Generic platform for conductive charging: Recharge 11 kW unidirectional charger for wireless power transfer. high-voltage battery from power grid.

› Useable for Plug-In hybrid and electric vehicles › Vehicle pad incl. controls and power electronics › Electronic topology for worldwide charging use case › Ground pad incl. control unit and system functions Benefits Benefits › Galvanic isolated power transfer › Positioning system › Support wide range of AC grid voltages › Electronic topology for worldwide charging use case › Bidirectional charging possible › Topology for high power density package › Diagnostic via OBD / CAN FD › Charging power: 3.6 kW up to 11 kW (WPT class 1,2,3) › Charging power: Up to 11 kW › Air gap: Z up to 21 cm › Grid supply: AC in 110 V – 240 V/400 V › Air gap monitoring: Living + foreign object detection › Communication: WiFi and P2P › HV battery: DC out 220 V – 470 V › Positioning: LF magnetic system › Housing: IP6K9; 3 g RMS › Grid supply: AC in 110 V – 240 V, 1–3 phases › Software: Continental SW opt. AUTOSAR

Technical Information Technical › HV battery: DC out 220 V – 470 V › Interfaces: CAN FD, Power Line › Software: AUTOSAR based multicore

Technical Information Technical Communication Hybrid Electric Vehicle 32 33 HV Axle Drive and HV Boost Converter Charging Electrification

Axle Drive extended with charging functions for a wide Ensures an optimally controlled power flow between range of charging options. drivetrain or charging interface to the battery.

› In traction and recuperation mode, it works like a › Higher current at low battery voltage conventional Axle Drive › Silicon carbide technology › In charging mode, it substitutes the on-board charger Benefits Benefits › Water-cooled › Single speed transmission › Active discharge › Parking lock › Reduce DC fast charge time by 10 % › Up to 12 times faster charging than state-of-the-art › Increase machine efficiency by supplying › Charging mode: 1 and 3-phase AC charging SoC independent traction power › Charging mode: Bi-directional operation (Vehicle-2-X) › Current gradient: Up to 100 A /ms › Power: Up to 140 kW power › Efficiency: > 98 % › Torque: Up to 3,100 Nm › DC-link Voltage: Variable up to 800 V

› Charging power: Up to 43 kW (4 km/min) Information Technical › 800 V fast charging with 400 V battery

Technical Information Technical AC charging › Power: Up to 150 kW › DC-link Voltage: Variable up to 800 V (at 800 V/400 V conversion) Engine Systems 34 35 Vehicle Control Unit 48 V eCompressor Electrification

Calculates and distributes torque request to various power- Electrically-driven radial compressor to improve transient train control units (engine, e-motor, battery, transmission). response and low end torque.

› Enables CO2 savings via predictive driving algorithms › Extended boost duration › Communications gateway › Allows optimized turbo matching

Benefits › For passenger vehicles (12 V) Benefits › Compensates impact of reduced scavenging › Supports fuel economy concepts › Central home for connected functions leads to reduced number of ECU variants › Customer specific aerodynamic design › Favorable acoustic characteristics › Core: Tricore multicore architecture › Permanent-magnet synchronous motor with low › Flash size: Up to 16 MB harmonic content › Interfaces: CAN FD, LIN, FlexRay, SENT, Ethernet › Supply voltage: 48 V › Drivers: High-/low-side, H-bridges › Peak shaft power: 5 kW › Housing: Plastic, 2 connector chambers › Response time: < 250 ms › Connector pins: 68 › Water-cooled

Technical Information Technical › › ISO 26262, AUTOSAR 4.2 CAN interface Technical Information Technical › High speed bearing system Hybrid Electric Vehicle 36 37 48 V Air-Cooled 48 V Liquid-Cooled Belt Starter Generator (BSG) Belt Starter Generator (BSG) Electrification

Cost-efficient, compact solution for mass hybridization. High performance, cost efficient mild hybrid solution. Advanced start-stop, coasting, and electric boost. Advanced start-stop, coasting, and electric boost.

› Air-cooled BSG with high power density and › Liquid-cooled BSG with highest power density integrated inverter › Generates high CO2 benefits together with › Generates high CO benefits together with significant drivability improvements

Benefits 2 Benefits significant drivability improvements › IP6K9K, robustness against water and dirt › Peak torque: 60 Nm › No debris/dust, no service required › Peak power: 12 kW in generator mode › Peak torque: 60 Nm › Speed: Up to 20,000 rpm continuous › Peak power: 15 kW in generator mode › Weight: < 10 kg › Speed: Up to 20,000 rpm continuous › Ambient temperature: –40°C up to +120°C › Weight: < 12 kg › Cold start approved at –30°C › Ambient temperature: –40°C up to +140°C Technical Information Technical › Stack length adjustable (40 up to 80 mm) › Cold start approved at –30°C

› Safety: ASIL-B Information Technical › Stack length adjustable (40 up to 80 mm) › Safety: ASIL-B Hybrid Electric Vehicle 38 39 48 V DC/DC Converter 48 V Battery Management System Electrification

Stabilizes and connects the 12 V power net and 48 V power Manages all functions of the 48 V Li-Ion battery. Cells are net for advanced start-stop, coasting, and electric boost. individually balanced and operated under safe conditions.

› Bi-directional DC/DC converter 48 V – 12 V › Measurement of cell voltage, battery current, and cell temperature › 12 V boardnet stabilization › Integrated cell balancing Benefits › Pre-charging function for 48 V DC-link Benefits › Contactor control and pre-charge function › Self-protection › Calculation of state of charge, available power, and › Digital voltage and current control battery health › Power (buck mode): Up to 3 kW cont.; 215 A › Complete circuitry on 1 single Printed Circuit Board › Power (boost mode): Up to 2.8 kW cont.; 58 A › Crash signal sensing and reaction › Efficiency: > 95% › Supervises up to 14 cells › Input voltage: 24 V up to 54 V › Quiescent current: < 250 μA (VDA320 compl.) › Cell voltage measurement range: 0 V up to 5 V › Output voltage: 6 V up to 16 V › Operating temperature: –40°C up to +85°C

Technical Information Technical › Protection class: IP6k2 › Battery current: +/-500 A (with 100 μOhm shunt) Technical Information Technical › Safety: ASIL C › AutoSAR compliant software Transmission 40 41 Control Unit for Control Unit for Stepped Double Clutch Transmission Automatic Transmission Electrification

Control unit for wet 6-speed Double Clutch Transmission Control unit for 7-speed Stepped for hybrid applications and electrified powertrains. Automatic Transmission and Electric Transmission Oil Pump.

› Control module including sensorics › Integrated in transmission › Control of clutch and gearshift actuators › Mechatronic module mounted on valve body Benefits Benefits › Additional control of disconnection clutch to the › Control of additional transmission oil pump for e-motor full electric drive › Control of electrical oil pump › Substrate: LTCC › Substrate: Bare-Die High-Density Interconnect › Operating temperature: –40°C up to +140°C › Operating temperature: –40°C up to +140°C › 32-bit microcontroller › 32-bit microcontroller › Sensors: 3 speed, 1 pressure, 2 temperature 1 position selector lever, 2 pressure switch › Sensors: 2 temperature (integrated), 1 rotary position, 2 speed, 3 pressure, 4 gear shift position › Actuators: 10 power outputs for solenoids

› Actuators: Connectors to 11 valves Information Technical

Technical Information Technical › Functional safety level: ASIL B Sensors & Actuators 42 43 Electrical Water Pump Temperature Sensor Coolant Electrification

Centrifugal pump based Temperature measurement. on a modular design concept.

› Supports energy management (on demand) › Clip or screw-in design › Operation independent from main cooling circuit › Wide range of applications and from combustion engine operation Benefits Benefits › High accuracy › Wet-running permanent-magnet rotor › Short response time › Electronically sensorless field-oriented commutated › Long-term stability BLDC motor › Differential pressure: 500 hPa up to 900 hPa › Engine coolant temperature: – 40°C up to +140°C › Volume flow: 700 l/h up to 2.400 l/h › Accuracy: ± 1°C (at 0°C) › Electrical power: Max. 130 W › Response time: up to 3 s › Hydraulic power: 10 W up to 53 W Technical Information Technical › Coolant temperature: –40°C up to +125°C › Dimensions (without Outer Ø ~82 mm connector and coupling): Length ~89 mm Technical Information Technical › Weight: < 700 g Sensors & Actuators 44 45 Coolant Flow Control Valve Coolant Flow Control Valve Non-Smart Smart Electrification

Rotary valve is used for shutting off the coolant flow, swit- Rotary valve is used for shutting off the coolant flow, switching over coolant circuits, and regulating the coolant flow. ching over coolant circuits, and regulating the coolant flow.

› Affordable price and full functional range › Affordable price and full functional range › Applicable for ICE, and xEV environment › Applicable for ICE, and xEV environment

Benefits › Valve and actuator produced by Continental Benefits › Valve and actuator produced by Continental › Modular and flexible design › Modular and flexible design › Full movement range, high speed › Full movement range, high speed › Non-contacting position sensor › Smart (integrated electronics), electrical fail safe

› Temp. range environment: –40°C up to +125°C › Temp. range environment: –40°C up to +125°C › Temp. range fluid: –40°C up to +135°C › Temp. range fluid: –40°C up to +135°C › Movement speed: < 2 s over 180° › Movement speed: < 2 s over 180° at 13.5 V and RT at 13.5 V and RT › Tube inner diameter: 16 mm › Tube inner diameter: 16 mm › Communication interface: PWM › Communicaiton interface: LIN › › Technical Information Technical Robust against external magnetic fields Information Technical Robust against external magnetic fields Hybrid Electric Vehicle 46 47 12 V Dual Battery 12 V Power Net System Management System Electrification

Enables a stable 12 V boardnet by managing the energy Supports the 12 V boardnet flow between two batteries. during peak demand, e.g. start-stop.

› Stabilized power net › Second power source (in serial connection) › Extended start-stop (< 20 km/h) › Supplies additional electric energy for starting and re-cranking, and during engine idle and coasting Benefits › Engine-off coasting Benefits › Regeneration › High number of load cycles › Passive boost › Recuperation of electric energy › 4% fuel savings on top of start-stop savings › Very low ohmic energy storage DLC › Power switch: 0.3 μOhm up to 1 μOhm › Energy management and diagnosis, (bi-directional or e.g. State of Charge uni-directional) › CAN or LIN communication › Current capability: 200 A cont. 1600 A peak › Current measurement: +/–100 A up to +/–1000 A Information Technical › Optional Battery Management Technical Information Technical Sensors & Actuators 48 49 Brushless DC Motor for Brake Applications

BLDC motor of an innovative braking system.

› Small package, low weight › Low content of rare earth material

Benefits › Symmetrical Back EMF layout › Low inertia, high torque, and speed due to high efficient BLDC motor concept

› Motor size: Ø 80 mm, lenght 89 mm › Motor torque constant: Up to 4.5 Nm at 90 A › Performance class: Up to 1,400 W in peak Doing more. For Clean Power. › Temperature range: –40°C up to +120°C Powertrain › Vibration resistant: Up to 40 g › Actual load capability: Up to 10 kN Technical Information Technical Connectivity Solutions 50 51 Connectivity Solutions

Connectivity Saves Fuel. In the past, energy management in vehicles func- tioned “on demand” – meaning that no matter how Connectivity intelligently designed the controls within the combustion engine or the electric motor drive were, they still only reacted to the driver’s foot on the pedal. We are opening up new potential for efficiency with the principle of Connected Energy Management (CEM): By connecting the vehicle with its environment through eHorizon and vehicle-to-X communication, the CEM can factor in the road conditions ahead in time. This helps us gain valuable additional percentage points in vehicle efficiency solely on the basis of software and intelligent, forward-thinking operating strategies. The concept also involves a bidirectional flow of data that other road users benefit from, too. In addition, this innovative approach is useful for all drivetrain configurations in passenger cars and commercial vehicles, from combustion engines to hybrids and electric cars. However, the biggest advantage emerges when it is used in conjunction with electric vehicle technology. Con- nectivity saves fuel. Sensors & Actuators 52 53 Door Handle Sensor Door Handle Sensor with NFC Reader

Sealed module integrating various keyless access Sealed module integrating lock/unlock functions (PASE) Connectivity functions into a door handle or exterior module. and vehicle access with smartphone or smart card.

› Easy integration of various functions for PASE › NFC function integrated into stand alone module system: Capacitive sensor, NFC reader, BLE trans- › Vehicle sharing, fleet management ceiver, inductive or mechanical switch, LF antenna,

Benefits lighting, Hall IC Benefits › Back-up to BLE for smartphone as a smart key › Various communication protocol: Current › Smartphone comptability with most smartphones modulation, voltage output, LIN, CAN. › No risk of relay attack due to short detection distance › Fully sealed stand alone module › Vehicle personalization and vehicle status

› Power consumption: < 100 μA for double › NFC protocols ISO/IEC 14443a, ISO/IEC18092:2013 capacitive sensor › NFC range: up to 40 mm › Typical response time: 30 ms › Dark current: 110 uA for NFC function › Detection distance: Up to 10 mm, depending (lock/unlock) on door › Single MCU for capacitive sensors and NFC function handle type › Temperature range: –40°C up to +85°C › Antenna inductance: From 100 μH up to 400 μH › Reaction time: ~ 100 ms Technical Information Technical › Temperature range: –40°C up to +85°C Information Technical › Communication: LIN, CAN Sensors & Actuators 54 55 Door Handle Sensor Easy Trunk Access Sensor BLE

Door Handle Sensor with BLE reader. Sealed capacitive sensor module integrated inside Connectivity a bumper for keyless access to the trunk or sliding doors.

› BLE function integrated into sealed stand alone › Easy hands-free opening or closing of the trunk or module sliding doors › Vehicle sharing, fleet management › Sensor activated with movement of the leg (no need Benefits Benefits to press a button or remote control) › Smartphone compatibility with most smartphones › Integration of capacitive sensor inside a bumper › Vehicle personalization and vehicle status › Dual electrode set to prevent false activations › BLE protocols: 4.2 › Detection distance: Up to 15 cm (tunable to › Single module for capacitive and BLE function application) › Communication: LIN, CAN › Quiescent current: 2.5 mA (no low power mode), › BLE range: 10 m (free field) 250 μA (low power mode) › Dark current: ~ 50 µA for BLE function › Temperature range: –40°C up to +85°C › BLE scanrate: ~100 ms › LIN, ON/OFF voltage or current output

Technical Information Technical › Temperature range: –40°C up to +85°C › Vehicle integration guidelines available for specific Technical Information Technical configurations (trailer hitch, US radars, etc.) Combustion Solutions 56 57 Combustion Solutions

Efficiency is Everything. Fuel is valuable. For this reason, one of our stated goals is to convert it into drive energy as effectively Combustion and cleanly as possible. State-of-the-art injection technology for gasoline and diesel, high-performance engine control units and exhaust gas turbo charging play a key role. However, sensor technology and actuators are be- coming key areas of specialization, as they increase control precision to a level that almost no one would have believed possible in series production just a few years ago. Additionally, combustion can be optimized even further, if we think in terms of whole systems: In a hybrid vehicle with a 48V system, for example, new possibilities open up for optimizing the internal combustion engine. We utilize these opportunities because as long as combustion engines are around, we believe that it is our job to get the most out of the drive technology – from fuel delivery to optimal atomization. Efficiency is everything. types of applications. non-automotive types all in For engines 4 stroke 2and 1 cylinder, multiple or Fuel Delivery Module Customized Systems Engine Technical Information Benefits › requirements › › areas › › › ›

Can provide simple assembly as “pump-on-a-stick” as assembly simple provide Can specific to customer validated and Designed connector electrical and line fuel Customized hard-to-reach from fuel pulls pump jet Integrated switches levels low and units sending Fuel level plastics conductive Electrically flanges plastic and Metal 58 nology to deliver liquid diesel fuel into the exhaust path. path. exhaust intothe fuel diesel liquid to deliver nology tech- robust and asimple provides system dosing The Injector Dosing Diesel Technical Information Benefits biodiesel, and increased engine durability engine increased and biodiesel, of tolerance greater intervals, change oil longer NO Efficiency High › › › › › › › › › › › ytmmnmmplewdh 10 to up 20 ms ms width: pulse minimum System continuous 500°C temperature: nozzle spray Max. 120°C temperature: valve control Max. pressure: System 75 to up μm 150 μm (SMD): Diameter Mean 0.1Sauter toup g/s 6g/s flow: of Accuracy range: mass fuel Delivery timing regeneration for flexibility of degree Higher to leads injection by post dilution oil of Avoidance technologies injection existing Uses and (DPF) Filter Particle Diesel for approach Robust X Trap (HENT) regeneration Trap (HENT) Up to 8.5 bar toUp 8.5 +/–7% 59

Combustion Engine Systems 60 61 Diesel Fuel Rail Diesel High Pressure Pump DHP1.1

Diesel fuel rail with flexible, proven, and robust design Next generation of diesel common rail high pressure for a high variety of customer specific solutions. pump. Platform is basis for future pump applications.

› Weight-reduced design › Digital Inlet Valve (DIV) supports low inlet pressure for high efficiency and low noise › Modular concept suitable for different engine sizes › DIV enables efficient fuel supply and highly precise (3 to 8 cylinder) Combustion Benefits Benefits and responsive fuel pressure control › System pressure: 2,500 bar › Compact package and light weight › Forged rail › Applicable also for light duty vehicles › Integrated pressure sensor › Pressure: Up to 2,500 bar › Option to integrate Pressure Decay Valve (PDV) › Displacement: 0.40 ccm/revolution › Weight: < 3 kg

Technical Information Technical › Length: < 80 mm › Drive: Belt, chain, gear › Rotation: Clockwise, counter clockwise

Technical Information Technical › Radial 1-piston pump: 2 lobes/rev Engine Systems 62 63 Diesel High Pressure Pump Diesel High Pressure Pump DHP2 DHP3

Common rail pump for passenger cars and light duty Diesel high pressure pump with small vehicles. size and light weight supporting common engine sizes.

› Compact package and light weight › Smart design for cam drive technology › High lifetime › Reduced leakage behavior Combustion Benefits › Worldwide fuel compatibility Benefits › Improved worst-case diesel capabilities › Applicable also for light duty vehicles › Pressure: Up to 2,200 bar › Based on proven platform technology. › Displacement: Up to 0.58 ccm/revolution › Weight: < 4 kg › Pressure: Up to 2,500 bar › Length: < 80 mm › Displacement: 0.23 ccm/stroke › Drive: Gear (belt, chain optional) › Weight: 800 g › Rotation: Counter clockwise › Camshaft with up to 4 lobes possible

Technical Information Technical (clockwise optional) › Digital Inlet Valve (DIV) supports low inlet pressure › Radial 2-piston pump: 2 strokes/revolution for high efficiency and low noise

› Volume metering: Volumetric Control Valve (VCV) Information Technical › DIV enables efficient fuel supply and highly precise and responsive fuel pressure control Engine Systems 64 65 Diesel Piezo Common Rail Diesel Pressure Decay Valve Injector PCRs5 PDV 1-25

Latest generation of servo-driven piezo common rail Latest generation of injector. diesel common rail digital high pressure regulator.

› Field-proven piezo technology › PDV enables pressure control with only one controller › High injection precision to meet Euro 6c / US Tier 3 for pump inlet and outlet metering – volume control ULEV 70 emission standards › High efficiency pressure control – only activated for Combustion Benefits Benefits › Excellent NVH performance volume decay › No permanent leakage enables start-stop capability › Benchmark in controllability and response capability › Compact package and light weight › Pressure: Up to 2,500 bar › Minimum quantity: ≤ 1.0 mm³/stroke for › Pressure: Up to 2,500 bar multiple injection patterns › Valve type: Digital currentless closed › Multiple injection: Up to 7 › Control type: Digital voltage signal › Minimum hydraulic dwell: 150 μs › Weight: < 220 g › Total leakage: < 30 ml/min at 2,000 bar (no permanent) › Length: < 55 mm (mounted) Technical Information Technical › Nozzle hole diameter: ≥ 90 μm Technical Information Technical Engine Systems 66 67 ECU Bi-Fuel ECU Diesel Ready-to-Use EasyU Heavy Duty Engines

Scalable, modular ECU for bi-fuel Scalable, modular, validated electronic platform for diesel applications. One electronic for gasoline PFI, CNG, LPG. solenoid medium and heavy duty engines.

› Mature validated HW and SW platform › Diesel engine management for amplified common › Standardized, validated electronic chipset rail and pump-line-nozzle and other solenoid injection systems Combustion Benefits › Engine management control unit or interface box Benefits for CNG, LPG › On-engine mounted with damping elements › Chassis mounted › Fulfills current emission requirements (EPA 2010+, Euro VI+, combined with SCR) › Supports up to Euro 5 › Core: TC1797 › Core: Monaco, 80 MHz › Flash size: 1.5 MB › Flash size: 4 MB › Interfaces: CAN, LIN, K-Line › Interfaces: CAN › Injector drivers: 4 PFI + 4 CNG / LPG P&H injector › Injector drivers: 12 › Driver outputs: 37 + 1 H-bridge + 4 IGBTs › Driver outputs: 21 + 1 H-bridge › Tightness: IP6K9K › Tightness: IP69K, IP67 Technical Information Technical

Technical Information Technical › Connector pins: 115 › Connector pins: 141 Engine Systems 68 69 ECU Diesel ECU Diesel Platform Piezo Common Rail for Commercial Vehicles

Scalable, modular, validated electronic, and SW platform Scalable, modular electronic platform for diesel solenoid with standardized chipset for various engines. medium and heavy duty engines.

› Controls piezo servo drive injectors, high pressure › Integrated after-treatment functions pump, and SCR subsystem (sensors and actuators) › Standardized, scalable, and modular electronics › Supports Euro 6c Combustion BenefitsBenefits Benefits › On-engine mounted with dampers › Core: Multicore architecture Tricore and › 12/24 V universal voltage Power PC › Supports Euro VI and Euro VI+ › Flash size: 2.5 MB up to 8 MB › Core: Multicore TC297 › Interfaces: CAN, LIN, FlexRay, SENT, PSI5 › Flash size: 8 MB › Injector drivers: 3 up to 8 piezo › Interfaces: CAN, CAN FD, LIN › Driver outputs: High-/low-side, up to 5 H-bridges › Injector drivers: Up to 6 cylinders, 3 banks Technical Information Technical › Housing: Aluminum or magnesium › Driver outputs: 59 + 3 H-bridges › Connector pins: Scalable up to 336 › Tightness: IP6K9K › ISO 26262, AUTOSAR 4.2 Technical Information Technical › Connector pins: 248 Engine Systems 70 71 ECU Gasoline ECU Gasoline Port Fuel Port Fuel Injection Injection Ready-to-Use EasyU

Scalable, modular, validated electronic, and SW platform Scalable, modular electronics, and SW for various engines. with standardized chipset for various PFI engines. Configurable off-the-shelf engine control unit.

› One flexible design for all Euro 6 PFI engines › Mature validated HW and SW platform for various vehicle configurations: EOBD, VVT, EGR, turbo, VIM, › 3/4 cyl engine feed with gasoline, flex-fuel (ethanol), PORT, and start-stop

GPL Combustion Benefits Benefits › Fast time to market › Chassis-mounted, engine bay › Supports Euro 6 › Core: TC275, 200 MHz › Core: Monaco /Andorra › Flash size: 4 MB › Flash size: 1, 1.5, 4 MB › Interfaces: CAN, CAN-WakeUP, LIN, SENT › Interfaces: CAN, CAN-WakeUP, LIN, SENT › Injector drivers: 4 PFI, CNG, E100 › Ignition driver: Internal IGBT or external › Driver outputs: 38, 3 H-bridges › Injection drivers: 4 PFI › Tightness: IP6K9K › Tightness: IP6K9K, IP67

Technical Information Technical › › Connector pins: 160 Information Technical Connector pins: 128 › Housing temp. range: –40°C up to +105°C

› Binary and linear O2 sensor Engine Systems 72 73 ECU Gasoline SDI and TCU ECU Gasoline SDI Ready-to-Use EasyU

Scalable, modular, validated electronic, and SW platform Scalable, modular electronics, and SW for various engines. with standardized chipset for various engines. Configurable off-the-shelf engine control unit.

› Combined control unit for gasoline solenoid direct › Mature validated HW, SW, and calibration platform injection and transmission control › Standardized electronic chipset › FF 8AT automatic transmission control with 6AT Combustion Benefits Benefits › HW, SW basic configuration ready for production and CVT functional capability › Fast time to market › Chassis-mounted › Supports Euro 6 / 6c › Supports Euro 6 / 6c › Core: TC277, 200 MHz › Core: EMS TC277, 200 MHz; TMS TC275, 200 MHz › Flash size: 4 MB › Flash size: EMS 4 MB; TMS 4 MB › Interfaces: CAN, CAN FD, CAN-WakeUP › Interfaces: CAN, CAN FD, LIN › Injector drivers: 4 SDI + 4 PFI › Injector drivers: 4 SDI › Driver outputs: 34 + 4 H-bridges › Driver outputs: 48 + 6 H-bridges + 8 linear solenoids › Tightness: IP6K9K

› Tightness: IP69K Information Technical › Connector pins: 196 Technical Information Technical › Connector pins: 238 › Housing temp. range: –40°C up to +105°C Engine Systems 74 75 ECU Gasoline ECU M3B (Air Module) Solenoid Direct Injection

Scalable, modular and validated electronic, and SW plat- For 1 and 2 cylinder, 2 and 4 stroke engines up to 1,000 cc form with standardized chipset for various SDI engines. in motorcycles, scooters, lawn mowers, generator sets.

› ECU with multiple options: Variable valve lift control, › ECU with integr. electronic throttle body and sensors lambda control LIN/BIN, turbocharger › Cost optimization and easy mounting Combustion Benefits › Encryption for hardware protection (SHE) Benefits › Throttle body size: Ø 26 up to 50 mm › Supports Euro 6c › Versatile configuration › Core: Tricore and Power PC multicore architecture › Integr. TMAP sensor, ETC controller, monitoring unit › Flash size: 2.5 MB up to 16 MB › 32 bit microcontroller, 40 MHz › Interfaces: CAN FD, LIN, FlexRay, SENT, PSI5, › 1 MB ROM (flash), 36 KB RAM Ethernet › IP67 and IP6K9K (high pressure cleaning) › Injector drivers: 3 up to 6 SDI/PFI › Input and output with full diagnostics and protection › Driver outputs: High-/low-side, up to 6 H-bridges › Operating temperature range: – 40°C up to +85°C

› Tightness: IP6K9K Information Technical Technical Information Technical › 32 pin connector with spares for vehicle functions › Connector pins: Scalable up to 336 › CAN interface for diagnostics and reprogramming › ISO 26262, AUTOSAR 4.2 Engine Systems 76 77 ECU M3C ECU M4D Ride-By-Wire

For 1 and 2 cyl., 2 and 4 stroke engines up to 1,100 cc in me- For 1 up to 4 cylinder, 2 and 4 stroke engines running up dium to high end motorcycles, scooters, ATV, snowmobiles. to 16,000 rpm in high end motorcycles, scooters, ATV, etc.

› Extended I / O for improved functionality › Drives simultanously up to 2 individual electrical throttle bodies and 2 DC-motor actuators › Enhanced timer module and control capability › Direct-drives up to 4 ignition coils (option: smart coils) Combustion Benefits › Robust mechanics with aluminum casing Benefits › Designed to meet Euro 5 with EOBD › 16 bit microcontroller, 16 MHz › 32 bit microcontroller, 120 MHz › 256 KB ROM (flash), 16 KB RAM › 2 MB ROM (flash), 128 KB RAM › IP67 and IP6K9K (high pressure cleaning) › IP67 and IP6K9K (high pressure cleaning) › Two knock sensor inputs › Separate safety monitoring unit for ETC system › Input and output with full diagnostics and protection › Operating temperature range: – 40°C up to +85°C › Operating temperature range: – 40°C up to +85°C › Single pocket 120-pins CMX connector Technical Information Technical

› 48 pin connector with spares for extended functions Information Technical › Dual CAN and LIN interfaces › CAN interface for diagnostics and reprogramming › 2 knock inputs, 2 linear + 2 binary O2 sensors › ISO 26262 compliant Engine Systems 78 79 ECU M4L/XE Air Module EMS3 Engine Management System Platform

For 1 cylinder, 4 stroke engines from 50 cc up to 250 cc in Electronic and SW EMS platform for powertrain: Gasoline, light motorcycles, scooters, lawn mowers, generator sets. diesel, commercial vehicle. Scalable for worldwide markets.

› ECU with integrated throttle body and sensors › For Euro 6+ diesel /gasoline drivetrain and electrical drive: PFI, SDI, PCR, Flex Fuel, CNG › Very compact size and easy mounting › Supports various engine sensors and actuators Combustion Benefits › Versatile configuration: Connector position, Benefits engine mounting interface, accelerator cable etc. › Improved power consumption and higher function integration › Euro 5, China stage 4, Bharat stage 6, OBDII › Up to 6 cores and 16 MB flash size › Throttle body size from Ø 16 mm up to 32 mm › Interfaces: CAN FD, LIN, FlexRay, SENT, PSI5, Ethernet › Integrated Throttle Position Sensor, Temperature Manifold Air Pressure, and Idle Speed Stepper › Generic Timer Module V3.1 (GTM) › 32 bit microcontroller, 32 MHz, 256 KB Flash › Injector drivers: 2 piezo up to 8 piezo, solenoid › IP66 and IP6K9K (high pressure cleaning) › Driver outputs: 16 up to 60, flexible high-/low-side › Operating temperature range: – 40°C up to +85°C › Connector pins: Up to 196 (300 in combination) Technical Information Technical

Technical Information Technical › 18 pin connector with spares for vehicle functions › ISO 26262, PowerSAR®: AUTOSAR 4.2, multicore freely distributable Engine Systems 80 81 Gasoline Deka 10 Gasoline Deka 7/9 Port Fuel Injector Port Fuel Injector

Features high flow range and reduced packaging, also for Flexible body, tip and spray configurations. twin /dual port engines, and non-automotive applications. Deka 9 with high flow range for turbocharged engines.

› Low minimum fueling with high linear performance › Various spray options and packaging configurations and low voltage sensitivity › Low minimum fueling with high linear performance › Combustion Improved leakage and extended operating pressures and low voltage sensitivity Combustion Benefits Benefits › Extra short length 23 mm available › Improved leakage capabilities and extended operating pressures › System pressure: 4 bar (max. 12 bar) › System pressure: 4 bar (max. 9 bar) › Static flow rate: 0.50 g/s up to 10.0 g/s › Static flow rate: 0.95 up to 6.0 g/s (Deka 7), › Linear flow range: 15:1 0.5 up to 8.0 g/s (Deka 9) › Tip leakage: <1.8 μl/min (3 bar, Exxsol), › Linear flow range: 10:1 <0.5 μl/min (Partial Zero- Emission Vehicle (PZEV) option › Tip leakage Deka 9: < 1.8 μl /min (3 bar, Exxsol), available) < 0.5 μl /min enhanced for Technical Information Technical › Fuel compatibility: Gasoline and flex fuel Partial Zero Emission Vehicle (up to E100/M30) Information Technical (PZEV) application › Fuel compatibility: Gasoline + flex fuel (up to E100) Engine Systems 82 83 Gasoline DI XL3.1 Gasoline DI XL5 Solenoid Injector Solenoid Injector

Gasoline Direct Injection (GDI) injector for natural For natural aspirated and downsized turbocharged aspirated and turbocharged engines. engines and future exhaust emission legislation.

› Improved linear flow range for high turbocharged › Euro 6d capable (WLTP, RDE) engines, suitable for side and central injection › Excellent mixture preparation and combustion › High flexibility of spray characteristics Combustion Combustion Benefits Benefits › Modular design for installation with small packaging › Low temperature capable O-rings requirements › Enhanced nozzle geometry for Euro 6c spray › Worldwide fuel compatibility performance › Worldwide fuel compatibility › System pressure: Up to 350 bar

› Pressure: Up to 250 bar › Minimum dynamic flow: 1.5 mg/stroke at 200 bar with controlled solenoid injection › Static flow range: Up to 20 g /s functionality HW and SW (COSI 2) › Minimum dynamic flow: ~2.0 mg /stroke › Hydraulic dwell time: 800 µs at 250 bar with controlled solenoid injection (COSI) › Multi-stream technology: Max. 7 holes › Multiple injection: < 800 µs hydr. dwell time › Nozzle hole drillling technology: µEDM or Fs-Laser › Multi-stream technology: Max. 7 holes Information Technical › Nozzle hole drilling techn.: µEDM or Fs-Laser Technical Information Technical Engine Systems 84 85 Gasoline Fuel Rail Gasoline High Pressure Pump Assembly GHP2.5 DI/PFI

GDI

PFI

Gasoline fuel rail Modular pump with an operational pressure up to 350 bar assembly for low and high pressure applications. to maintain the future injection pressure levels.

› GDI: Modular rail portfolio to support customer › Increased robustness level specific solutions clamped and suspended › Toolbox for balance of flow delivery vs. load and › Combustion Weight optimized rail architecture – torque Combustion Benefits Benefits up to 10% improvement › Low parasitic losses inside pump › Pressure sensors optional › Low operating noise level › PFI: Customer specific solutions available › Dual system (DI/PFI) feeding via HP Pump › GDI: Fuel rail assembly up to 350 bar › System pressure: Up to 350 bar › Accurate injector orientation for optimal spray target › Engine speed: Up to 7,500 1/min › PFI: Plastic and stainless steel fuel rails › Max. flow (theoretical): Up to 1.005 cc/rev, › Fuel rail assembly up to 9 bar 1.41 cc/rev (HF) › Optional internal damper › Piston diameter: 8 mm, 10 mm (HF) › E100 capability including SVS injection › Fuel: Standard fuels compatible,

Technical Information Technical optional bad fuel version Technical Information Technical GHP2.5 Gasoline High Pressure Pump Modular pump with an operational pressure up to 350 bar bar levels. pressure 350 to injection future up the to maintain pressure operational an with pump Modular Systems Engine GHP2.5 Technical Information Benefits

› › › › › › › › › ›

Fuel: Fuel: diameter: Piston (theoretical): flow Max. speed: Engine pressure: System packaging Flexible level noise Low operating pump inside losses Low parasitic torque and load vs. delivery flow of Toolbox balance for level robustness Increased optional bad fuel version fuel bad optional compatible, fuels Standard 8 mm, 10 (HF) mm (HF) 1.41 cc/rev toUp 1.005 cc/rev, toUp 7,500 1/min toUp 350 bar GHP2.5 High Flow High GHP2.5 86 reduced turbocharger with thermal advantages. thermal with turbocharger reduced cost and Weight Aluminum TurbineHousing Gasoline Turbocharger with Technical Information Benefits

› › › › › › › › › › ›

Both Both rotational directions available actuation waste-gate electric or Pneumatic to up m/s 580 speed Rotational to up 1050°C temperature Exhaust wheel compressor Milled thermodynamics edge cutting for design wheel specific Application housing turbine aluminum Water-cooled oil and water of heat-up faster Ensures soak heat during coaking oil Prevents power rated at combustion Facilitates stoichiometric shields heat of elimination and cost material by lower reduction Cost

Combustion performance. performance. thermodynamic Benchmark Systems Engine Steel Steel TurbineHousing Gasoline Turbocharger with Technical Information Benefits electrical wastegate actuator from Continental from actuator wastegate electrical economy fuel best and drivability, thermodynamics, screws tie-rod › › › › › › › › › ›

Optional electrical compressor bypass valve and and valve bypass compressor electrical Optional actuation waste-gate electric or Pneumatic to up m/s 580 speed Rotational to up temperature 1050°CExhaust wheel compressor Milled housing bearing Water-cooled system sealing effective Highly edge cutting for design wheel specific Application with connection housing turbine/center Patented RAAX™ turbine technology for best transient response transient best for technology turbine RAAX™ Robust and reliable design. reliable and Robust 88 with variable inlet guide vanes for improved time to torque. time improved for vanes guide inlet variable with technology turbine VRAAX™ VRAAX™ Turbine Technology Gasoline Turbocharger with Technical Information Benefits characteristics › › › › › › › › › › ›

Pneumatic or electric wastegate actuation wastegate electric or Pneumatic 980°C / to up T3 950°C cooling water without or with housing Bearing to up m/s 580 speed Rotational wheel compressor Milled shape 3D vane with turbine geometry Variable scavenging reduced of impact Compensates thermomechanical improved for concept Cartridge response transient superior for Low inertia controllability excellent for hysteresis Benchmark behavior wear enhanced design, reliable and Robust 89

Combustion Ignition Coil Ignition For mopeds, scooters, light motorcycles, lawn mowers, mowers, generators. power lawn electric motorcycles, light scooters, mopeds, For Engine Systems Engine Technical Information Benefits › › › › › › › › › › ›

Recomm. cable size (mm2): 2.0 up to up 2.5 2.0 to up 3.5 2.5 Ø(mm2): overall cable Recomm. size (mm2): cable Recomm. diode ms suppressor +0.2 ms voltage 0.5 High (1,000Arc duration V Zener): A 3.3 14 V +0.5 V time: Dwell current: primary Maximum supply: voltage Nominal connector primary Standard connector voltage high Standard integrated diode voltage High coil size inductive Small < 6 ms 90 engines in all types of non-automotive applications. non-automotive of types all in engines For 4 stroke 2and 1 cylinder, multiple or Oxygen Sensor Technical Information Benefits pumping method against water splash water against method pumping › › › › › › › › › ›

Heater resistance: 8.1 pumping Self resistance: Heater ohm M12 air: Reference 35 mm size: Thread mm 500 length: Body 4wire length: Cable wire: Lead Vibration resistance droplets to water Resistant current injection uses which structure hermetic A environments for 2-wheeler developed Specifically 91

Combustion Sensors & Actuators 92 93 Active Purge Pump Air Control Valve Economy Line S11.1

Generates the flow of fuel vapors from an evaporative emis- Intake air pressure control for diesel combustion engines. sion canister to the manifold of limited vacuum engines. Supports EGR and particle filter regeneration on diesel engines. Full plastic design concept. › HC purging is independent from manifold vacuum › Low cost performance, full functional range › OBD monitoring for HC evaporative leak detection › Low weight, small package Combustion Benefits › Low power consumption (~30 W) Benefits › Good crash behavior › Compact size for vehicle packaging › Capable for turbo applications

› Radial pump with integrated electronics › Temperature range: –40°C up to +140°C › Purge flow: 50 slpm at 10 kPa at 10.5 V, › Response time (typ.): 110 ms (13.5 V, RT) RT, dry air › Pressure range: Up to 3.5 bar peak › Operating temp.: –40°C up to +120°C › Leakage (at stop): < 2.8 kg/h (TP Ø 48 mm) › Brushless DC motor: ~30 W › TP Ø range: 40 mm up to 57 mm › Feedback for speed and torque Technical Information Technical Technical Information Technical Sensors & Actuators 94 95 Air Control Valve – Air Control Valve 12 – Performance Line S8.6 Modular Performance

Intake air flow and pressure control on combustion Intake air flow and pressure control on combustion engines. Supports EGR and particle filter regeneration. engines. Supports EGR and particle filter regeneration.

› Modular capable for 12 V and 24 V systems › Modular design concept, low weight, small package › Capable for big TP diameters – high flow › High torque, fast response Combustion Benefits › Capable for turbo and supercharged applications Benefits › Low leakage › Capable for turbo- and supercharged applications › Temperature range: –40°C up to +140°C › Temperature range: –40°C up to 140°C › Response time (typ.): 90 ms (13.5 V, RT) 180°C for high temperature › Pressure range: Up to 3.5 bar peak › Response time (typ.): 90 ms (13.5V, RT) › TP diameter range: 57 mm up to 100 mm › Pressure range: up to 3.5 bar peak › Signal output: Analog 5 V › Leakage (at stop): < 2.5 kg/h (TP Ø52 mm), < 3.5 kg/h for high temperature

Technical Information Technical › TP diameter range: 40 up to 95 mm Technical Information Technical › Signal output: Analog 5 V or digital SENT › Weight: 490 g (TP Ø48 mm with optimized housing) diesel applications. applications. diesel on regeneration filter particle EGR and Supports engines. combustion on control pressure and flow air Intake Cooled Water Performance Modular Air Control Valve 12 – & Actuators Sensors Technical Information Benefits › › › › › › › › › › › ›

Signal output: Analog 5 V or digital SENT 5 digital V or Analog output: Signal to up 95 40 mm range: diameter TP Ø 52 mm) (TP < kg/h 3.5 peak bar to Up 3.5 stop): (at Leakage range: Pressure (13.5V, ms (typ.): 90 time Response RT) to up 230°C –40°C range: Temperature applications temperature high very for Used applications supercharged and turbo- for Capable Low leakage package small very Low weight, response fast torque, High concept design Modular 96 High Efficiency High Drives DC Brushless use out of a scalable, modular concept. modular ascalable, of out use different for prices to reasonable motors performance Best Technical Information Benefits depending on customers’ customers’ on needs depending concept modular the rate filling copperwire etc. pumps oil AWD-disconnect, clutch, double › › › › › › ›

Temperature range: – 40°C up to up +140°C 40°C – range: Temperature windings and diameter, length of Variation 50 toW up 900 W classes: performance Different within capability speed high as well as torque High material earth rare of Low content to high due inertia low weight, low package, Small in use for drives DC brushless efficiency High 97

Combustion Sensors & Actuators 98 99 Canister Purge Solenoid Digital Linear Actuator CPS6 Compact Size – Gen VII

The Canister Purge Solenoid controls hydrocarbon Idle airflow control for two-wheeler and small engines. vapors from the canister to the intake manifold.

› Higher flow than competitive valves › Accurate and stable idle air control › Linear flow curve and fast response › Various gas (air) flow curve can be achieved Combustion Benefits Benefits › Sonic nozzle flow control › Light-weighted and small-sized robust design › Integrated particle trap to control contamination › High resolution linear positioning against load › Integrated noise attenuation volume › Two packagings for different integration options

› Flow at >30 kPa: 110 SLPM (2.3 g/s, 7.9 kg/h) › Operating voltage: 7.5 V up to 14 V › Operating voltage: 9 V up to 16 V (13.5 V optimal) › Inductance/winding: 20.7 mH › Coil resistance: 21 Ohms › Resistance/winding: 53 Ohms › OBD leakage (6.7 kPa vacuum on canister port): › Resolution: 0.042 mm/step (full step mode) < 3.0 SCCM › Total travel (typ.): 8.5 mm (204 steps) › Operating temp.: –25°C up to +125°C › Operating temp.: –30°C up to +110°C

› Information Technical Technical Information Technical Frequency: 5 Hz up to 32 Hz › Airflow control: Up to 41.8 kg/hr (10 Hz recommended) at ΔP = 600 hPa Sensors & Actuators 100 101 Digital Linear Actuator Digital Linear Actuator Standard Size – Gen I Standard Size – Gen II

Accurate and precise gas/airflow. Accurate and precise gas/airflow. Linear position control against external load. Linear position control against external load.

› Accurate and stable idle air control › Accurate and stable idle air control › Various gas (air) flow curve can be achieved › Various gas (air) flow curve can be achieved Combustion Benefits › High accuracy under severe conditions Benefits › High accuracy under severe conditions › Proven reliability and long durability › Proven reliability and long durability › High resolution linear positioning against load › High resolution linear positioning against load

› Operating voltage: 12 V (7.5 V – 14 V) › Operating voltage: 12 V (7.5 V – 14 V) › Resistance per winding: 53 Ohms › Resistance per winding: 48 Ohms › Linear resolution: 0.042 mm / full step › Linear resolution: 0.042 mm / full step › Total travel (typical): 8.5 mm (204 steps) › Total travel (typical): 8.5 mm (204 steps) › Operating temperature: –40°C up to +125°C › Operating temperature: –40°C up to +125°C › Vibration capability: Up to 40 G › Vibration capability: Up to 40 G Technical Information Technical Technical Information Technical › Life time durability: 500 hours › Life time durability: Up to 2,000 hours › Weight: Around 110 g › Weight: Around 90 g Sensors & Actuators 102 103 Digital Linear Actuator Electrical Compressor Standard Size – Gen V Bypass Valve

Accurate and precise gas/air flow. Compressor surge prevention and turbocharger lag Linear position control against external load. reduction by opening a bypass for the compressor.

› Accurate and stable idle air control › Electromagnetic on-off solenoid › Various gas (air) flow curve can be achieved › Improved performance and size Combustion Benefits › High accuracy under severe conditions Benefits › No vacuum lines, tank, or vacuum control valve needed › Proven reliability and long durability › Fast actuation › Plastic sleeve gives lighter weight › Mounted directly on turbocharger or air duct › Operating voltage: 12 V (7.5 V – 14 V) › Nom. operating voltage: 12 V › Linear resolution: 0.042 mm / full step › Response: <50 ms at 20°C; 13.5 V › Total travel (typical): 8.5 mm (204 steps) › Operation (gas) temp.: –40°C up to +180°C › Vibration capability: Up to 35 G short term (30 min.): +200°C › Life time durability: Up to 1,000 hours › Ambient temperature: –40°C up to +150°C › Weight: 45 g up to 53 g › Storage temperature: –40°C up to +200°C Technical Information Technical

Technical Information Technical › Travel: ≥ 5 mm; Poppet Ø 26 mm Sensors & Actuators 104 105 Electrical Exhaust Gas Electronic Throttle Control Recirculation Valve 11.2 – Economy Line

Controls the amount of recirculated exhaust gas to reduce Torque / load control on gasoline combustion engines. NOX emissions and fuel consumption. Supports idle speed, cruise, and traction control.

› Electric actuation has faster response and more › Low weight, small package control than conventional vacuum systems › Low leakage › Eliminates vacuum regulator and connecting hoses Combustion Benefits Benefits › Capable for turbo- and supercharged applications › Can be tailored to customer flow requirements › Temperature range: –40°C up to +140°C › Current consumption › Pressure range: Up to 2.5 bar peak at max. flow: 1.0 A at 20°C › Response time (typ.): 100 ms (13.5 V, RT) › Nominal operating voltage: 12 VDC › Leakage: < 2.5 kg/h (TP Ø 52 mm) › Max current consumption: 1.5 A › TP Ø range: 40 up to 68 mm › Nominal coil resistance: 8.0 Ohms at 20°C › Nominal operating frequency: 90 Hz up to 175 Hz Technical Information Technical

Technical Information Technical › Position sensor supply voltage: 5 VDC › Response time (total stroke): < 50 ms at 20°C, 13.5 VDC Sensors & Actuators 106 107 Electronic Throttle Control Electronic Throttle Control ETC 12 – Modular Perform. 13 – Economy Line

Torque/load control on gasoline combustion engines. Torque / load control on gasoline combustion engines. Supports idle speed, cruise, and traction control. Supports idle speed, cruise, and traction control.

› High performance throttle body actuator › Modular design concept › Modular design concept › Lowest weight with hybrid housing, very small

package Combustion Benefits › Low weight, very small package Benefits › › Low leakage, spherical bore optional Low leakage as regular aluminum housing › Capable for turbo and supercharged applications › Capable for turbo applications

› Temperature range: –40°C up to +140°C › Temperature range: – 40°C up to +140°C 180°C for high temperature › Response time (typ.): 100 ms (13.5 V, RT) › Response time (typ.): 90 ms (13.5 V, RT) › Pressure range: Up to 2.5 bar peak › Pressure range: Up to 3 bar peak › Leakage (at stop): < 2.5 kg/h (TP Ø 44 mm) › Leakage (at stop): < 2.5 kg/h (TP Ø 52 mm), › TP Ø range: 40 up to 57 mm < 3.5 kg/h for high temperature

› TP diameter range: 40 mm up to 95 mm Information Technical Technical Information Technical › Signal output: Analog 5 V or digital SENT Sensors & Actuators 108 109 Electrical Wastegate Exhaust Control Valve Actuator High Pressure

Performing waste-gate adjustment to optimize functional Helps to reduce emissions of NOX and fuel consumption application and reduce fuel consumption. in gasoline and diesel engines in HP EGR loop.

› Continuous adjustment of external application using › Balanced rotary throttle principle for EGR control rotating output shaft › Contactless MR Sensor, flexible output › Ideal for use in turbocharger applications Combustion Benefits Benefits › Provides accurate low flow precision › Option: Default position › High flow EGR with low gas pressure drop › Permanent feedback signal (contactless) › Fits high temperature and pressure pulsations › Max. external load › Torque at flap: 230 Ncm without return function: 92 Ncm › Response time (85%): < 80 ms › Max. continuous holding torque without return function at 140°C: 144 Ncm › Nominal supply voltage: 12 VDC or 24 VDC

› Holding torque › Position sensor supply voltage: 5 VDC capability at 140°C: 420 Ncm › Maximum flow: Up to 190 kg/h › Response time less than: 100 ms/80° angle at 160°C at 50 hPa Technical Information Technical

› Operation temperature: –40°C up to +160°C Information Technical › Exhaust temperature: Up to 700°C NO of emissions reduce to Helps Linear Exhaust Control Valve & Actuators Sensors Technical Information Benefits X

› › › › › › › › › › › and fuel consumption in gasoline and diesel engines. diesel and gasoline in consumption fuel and

epnetm t5: ≤100 ms dP at 120 100 kg/h hPa (t85): time Response flow: typical Max. adequate with >500°C temperature: gas Exhaust 5.0 V voltage: supply sens. Pos. 12 V voltage: supply Nominal customized be can interfaces + electrical Mechanical N to forceup 500 Opening design Compact leakage seat Low valve time response short and friction Reduced measurement) position (direct technology Linear (single poppet design) poppet (single cooling DC DC 110 Low Pressure Low Exhaust Control Valve in gasoline and diesel engines in LP EGR LP in loop. engines diesel and gasoline in Helps to reduce emissions of NO of emissions to reduce Helps Technical Information Benefits against magnetic fields fields magnetic against › › › › › › › › › › ›

xas a eprtr: 100°C up to 200°C temperature: gas Exhaust kPa 300 flap: over press. differential Max. 3kg/h h ≤ / kg 245 hPa): 600 dP (at leakage Internal 12hPa): 20 V dP (at flow Maximum 5 V voltage: supply sensor Position voltage: supply Nominal (t90): time Response EGR LP for path requirement to corrosion Adapted size light-weighted Compact, sensitive not output, flexible sensor, Non-contacting drop pressure small EGR with LP valve flow High X and fuel consumption consumption fuel and < 90 ms 90 < DC DC 111

Combustion mixture. mixture. fuel /ethanol gasoline in concentration ethanol Detects Flex Fuel Ethanol Fluid Sensor & Actuators Sensors Technical Information Benefits › › › › › › › › ›

temp.: Environmental Fuel temp. range: range: Pressure Accuracy: Accuracy: Capacitive (0% up to up content) 100% ethanol (0% Capacitive principle: Measurement Self diagnostic capability diagnostic Self within 250 ms after start-up 250 after ms within temperature fuel and concentration ethanol Outputs combustion / injection before detection ethanol Enables Highly accurate prediction of ethanol concentration ethanol of prediction accurate Highly –40°C up to up +150°C –40°C to up +90°C –40°C (145<10 bar psi) concentration ethanol 5% +/– 112 Passive Electrothermic Passive Level Oil – Sensor Fluid underfill during driving or at key-on. at or driving during underfill or tooverfill avoid level oil engine correct monitors Sensor Technical Information Benefits

› › › › › › › › › › ›

temp.: Operating interval: Measuring measurement: First approx.: Accuracy range: Measuring principle: Measuring optional measurement Temperature positions mounting Different dipstick oil of Replacement and dynamic conditions static in level oil of measurement Absolute indication level low and Overfill –40°C up to up +160°C –40°C s >10 key-on safter 0.6 Available mm +/–3 max. and min. 100 between mm Thermo-resistive heated wire heated Thermo-resistive 113

Combustion Sensors & Actuators 114 115 Fluid Sensor Fluid Sensor – Oil Level Oil Level Switch Ultrasonic

Level switch to monitor engine oil level below minimum Best price-performance threshold. ratio sensor to monitor correct engine oil level.

› Low oil level detection › Replacement of oil dipstick › Different connectors possible › Detection of low level and overfill Combustion Combustion Benefits › Simple on /off output Benefits › Absolute measurement of oil level static /dynamic › Market proven › Low power consumption › Temperature measurement optional › Measuring principle: Magnetic reed switch › Measuring principle: Ultrasonic echo › Different switch heights possible › Measuring range: 18 mm up to 150 mm › Normally on (switch closed) › Level accuracy: +/–2 mm › Tolerance: +/–1 mm › Power supply: 12 V/10 mA typical › Protection class: IP X9K › First measurement: Available after 0.4 sec. Technical Information Technical

Technical Information Technical › Measuring interval: 1 sec. › Interface: PWM Sensors & Actuators 116 117 In Cylinder Pressure Sensor Knock Sensor M6 Small Design

Real-time combustion sensing, providing in-cylinder Measures structural vibrations in the internal combustion combustion pressure information. engine to continuously adjust ignition parameters.

› Tolerance compensation (injection, airpath, engine, › Optimization of ignition timing for max. efficiency fuel, etc.): Combustion stability control › High sensitivity › System cost improvement: Intake/exhaust models Combustion Combustion Benefits Benefits › Small design with M6 bolt for space and weight › Airpath accuracy and dynamic control savings (O intake based) 2 › Increased engine power, decreased fuel consumption › Enables alternative combustion control (HCCI) › Fits for automotive, two-wheelers, and others › Embedded electronic using direct analog path – no time delay › Acceleration sensor-based on piezo ceramic technology with a range of: 0 g up to 400 g › Independent of glow plug, improved robustness and signal › Frequency range: 3 kHz up to 25 kHz › Large bandwidth suitable for diesel and gasoline › Possible integration of discharge resistor › Output signal: 0 V up to 5 V (ratiometric) › Glue and nut designs available › Measurement range: 0 bar up to 200 bar (adjustable) › Compatible with current ECU designs Technical Information Technical

› Temperature range: –40°C up to +150°C Information Technical Sensors & Actuators 118 119 Knock Sensor Latching Valve M8 Standard Design

Measures structural vibrations in the combustion engine Latching refueling valve is a bi-stable valve used to a seal- to continuously adjust ignition parameters. pressurized tank or isolated HC vapors in a normal tank.

› Optimized ignition timing for maximum efficiency › Significantly less energy consumption › High sensitivity › Maintains valve position using zero current draw Combustion Combustion Benefits › Compact design, nested bolt possible Benefits › Very low flow restriction › Increase engine power › Able to determine valve position (open/closed) › Decrease fuel consumption › Passive relief function for fuel tank over pressure

› Acceleration sensor-based on piezo ceramic › 14 V DC pulse for <100 ms to change valve state technology › Flow: >115 SLPM at 1.5 kPa › Frequency range: 3 kHz up to 25 kHz › Overpressure relief at 43.5 kPa › Possible integration of discharge resistor › Leak: <1 sccm at 5 kPa and 20 kPa tank pressure › Integrated connector or cable version › Leak: <3.5 sccm at 35 kPa tank pressure › Nut and glue types assembly technology › Leak: <10 sccm at – 9 kPa tank pressure Technical Information Technical Technical Information Technical Sensors & Actuators 120 121 Linear Purge Valve Natural Vacuum Leak Detection (NVLD III)

The Linear Purge Valve controls hydrocarbon vapors from Engine-off OBD monitoring for hydrocarbon evaporative the canister to the intake manifold. leak detection. Legislation compliance.

› Very low operating noise › With integrated electronics › Fast response for incremental flow control at all › OBD HC leak diagnostic performed after key off Combustion operating conditions Combustion Benefits Benefits › Integrated solenoid for improved purge flow capacity › Excellent low end flow control preventing unwanted › Passive over pressure venting (including refueling) surges of fuel vapor › Temperature sensing; Switch sensing › Typical flow: 70 SLPM at 57 kPa › Detection capable to 0.5mm diameter leak › Operating voltage: 14 V › Bit serial communication with ECU › Coil resistance: 14.0 Ohms › High in use monitor performance › Maximum current: 500 mA › Nominal coil resistance: 21 Ohms › Control circuit constant current at: 150 Hz up to 200 Hz › Operating temperature: –40°C up to +85°C

Technical Information Technical › Weight: 200 g › 100 SLPM purge flow: <6 mbar Δ pressure Technical Information Technical › 100 SLPM refueling flow: <7 mbar Δ pressure Sensors & Actuators 122 123 Pressure Sensor Pressure Sensor Brake Booster Absolute Brake Booster Gauge

Pressure measurement for start-stop applications. Relative measurement of vacuum inside brake booster.

› Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels › Precision programmable clip levels Combustion Combustion Benefits › Internal and output diagnostic capability Benefits › Internal and output diagnostic capability › High accuracy and temperature stability › High accuracy and temperature stability › Fulfills toughest EMC requirements › Flexible housing, connector, and mounting designs

› Pressure range: 10 kPa up to 120 kPa › Pressure range: –105 kPa up to 40 kPa (gauge) › Accuracy: 1% full scale (10°C up to 85°C) › Accuracy: 1% full scale (10°C up to 85°C) › Temperature range: –40°C up to +140°C › Temperature range: –40°C up to +125°C › Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V › Supply current at 5 V: 10 mA maximum › Supply current at 5 V: 10 mA maximum › Output signal: Analog or SENT › Load resistance: >4.7 kOhms Technical Information Technical Technical Information Technical › Output signal: Analog or SENT Sensors & Actuators 124 125 Pressure Sensor Pressure Sensor – Filter Control Gauge Filter Control Gauge

Air Filter Pressure

Relative measurement of pressure downstream of air filter. Relative pressure measurement used to monitor performance of intake air filter pressure measurement.

› Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels › Precision programmable clip levels Combustion Combustion

Benefits › Internal and output diagnostic capability Benefits › Internal and output diagnostic capability › High accuracy and temperature stability › High accuracy and temperature stability › Fulfills toughest EMC requirements › Fulfills toughest EMC requirements › Flexible housing, connector, and mounting design › Flexible housing, connector, and mounting design

› Adjustable characteristic via electronic calibration › Adjustable characteristic via electronic calibration › Pressure range: 0 kPa up to 10 kPa › Pressure range: –10 kPa up to 10 kPa › Operating temp.: –40°C up to +125°C › Operating temp.: –40°C up to +125°C › Supply voltage: 5 V +/– 0.25 V › Supply voltage: 5 V ± 0.25 V › Output signal: Analog or SENT › Output signal: Analog or SENT › Transfer function: Linear, ratiometric (analog version) › Transfer function: Linear, ratiometric (analog version) › Accuracy: 3% full span (10°C up to 85°C) › Accuracy: 3% full span (10°C up to 85°C) Technical Information Technical Technical Information Technical over full-scale over full-scale

Sensors & Actuators 126 127 Pressure Sensor – Pressure Sensor – Filter Control Gauge Filter Control Gauge

Diesel Gasoline Crankcase Crankcase Pressure Pressure

Relative pressure measurement used to monitor Relative pressure measurement used to monitor performance of positive crankcase ventilation system. performance of positive crankcase ventilation system.

› Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels › Precision programmable clip levels Combustion Combustion

› Adjustable characteristic via electronic calibration › Adjustable characteristic via electronic calibration › Pressure range: –10 kPa up to 10 kPa › Pressure range: 0 kPa up to 10 kPa › Operating temp.: –40°C up to +125°C › Operating temp.: –40°C up to +125°C › Supply voltage: 5 V ± 0.25 V › Supply voltage: 5 V +/– 0.25 V › Output signal: Analog or SENT › Output signal: Analog or SENT › Transfer function: Linear, ratiometric (analog version) › Transfer function: Linear, ratiometric (analog version) › Accuracy: 3% full span (10°C up to 85°C) › Accuracy: 3% full span (10°C up to 85°C) Technical Information Technical over full-scale Information Technical over full-scale Sensors & Actuators 128 129 Pressure Sensor – Pressure Sensor Fuel Vapor Gauge High Pressure Diesel

Relative pressure measurement used to detect any leak Direct measurement of pressure in diesel fuel rail. condition in evaporative fuel systems.

› Flexible calibration of transfer functions › High accuracy and temperature stability › Precision programmable clip levels › High vibration robustness (low / high frequencies) Combustion Combustion Benefits › Internal and output diagnostic capability Benefits › Modular design for connector and mounting › High accuracy and temperature stability › Flexible calibration of transfer functions › Fulfills toughest EMC requirements › Internal and output diagnostic capability › Flexible housing, connector, and mounting design › Pressure range: 0 bar up to 3,000 bar › Adjustable characteristic via electronic calibration › Pressure range: – 5 kPa up to 5 kPa › Temperature range: –40°C up to +140°C › Operating temp.: –40°C up to +125°C › Supply: 5 V, 10 mA › Supply voltage: 5 V ± 0.25 V › Output signal: Analog or SENT › Output signal: Analog or SENT › Accuracy: 0.5% full scale output › Transfer function: Linear, ratiometric (analog version) › Response time: <1 ms

› Accuracy: 1.5% full span (10°C up to 85°C) Information Technical Technical Information Technical over full-scale Sensors & Actuators 130 131 Pressure Sensor Pressure Sensor High Pressure Gasoline Manifold Absolute

MAP TMAP BAP

Direct measurement of pressure in gasoline fuel rail. Direct measurement of pressure in manifold.

› High accuracy and temperature stability › Flexible calibration of transfer functions › High vibration robustness (low / high frequencies) › High accuracy and temperature stability Combustion Combustion Benefits › Modular design for connector and mounting Benefits › Low cost design and high quality › Flexible calibration of transfer functions › Fulfills toughest EMC requirements › Internal and output diagnostic capability › Flexible housing, connector, and mounting design

› Pressure range: 0 bar up to 500 bar › Pressure range: 40 kPa up to 120 kPa (for BAP) › Temperature range: –40°C up to +140°C › Pressure range: 7 kPa up to 500 kPa (for MAP and Turbo MAP) › Supply: 5 V, 10 mA › Accuracy: 1% full scale (10°C up to 85°C) › Output signal: Analog or SENT › Temperature range: –40°C up to +140°C › Accuracy: 0.5% full scale output › Output signal: Analog or SENT › Response time: <1 ms Technical Information Technical Technical Information Technical Sensors & Actuators 132 133 Pressure Sensor – Manifold Pressure Sensor Absolute and Temperature Manifold Gauge

MAP with integrated temperature sensor directly Relative measurement of pressure or vacuum in the measures the pressure and temperature in the manifold. intake manifold.

› Flexible calibration of transfer functions › Flexible calibration of transfer functions › High accuracy and temperature stability › Precision programmable clip levels Combustion Combustion Benefits › Low cost design and high quality Benefits › Internal and output diagnostic capability › Fulfills toughest EMC requirements › High accuracy and temperature stability › Flexible housing, connector, and mounting design › Fulfills toughest EMC requirements

› Pressure range: 40 kPa up to 120 kPa (for TBAP) › Pressure range: –105 kPa up to 40 kPa (gauge) › Pressure range: 7 kPa up to 500 kPa › Accuracy: 1% full scale (10°C up to 85°C) (for TMAP and Turbo TMAP) › Temperature range: –40°C up to +125°C › Accuracy: 1% full scale (10°C up to 85°C) › Supply voltage: 5 V +/– 0.5 V › Temperature range: –40°C up to +140°C › Supply current at 5 V: 10 mA maximum › Output signal: Analog or SENT › Load resistance: >4.7 kOhms Technical Information Technical Technical Information Technical Sensors & Actuators 134 135 Temperature Sensor Temperature Sensor High Single Coolant / Fuel / Oil

Turbocharger Temperature measurement in several liquid media protection and exhaust temperature measurement. (coolant water, oil, fuel).

› Smart sensor with digital output, high accuracy › Clip or screw-in design › System price benefit › Wide range of applications Combustion Combustion Benefits › Stable signal over lifetime Benefits › High accuracy › Fast response due to small thermal inertia › Short response time › Proven high temperature robustness › Long-term stability

› Sensing technology: Thermocouple › Oil, water, fuel, temperature measurement › Response time: 8 sec. at 10 m/s flow – Engine coolant: –40°C up to +140°C – Engine oil: –40°C up to +150°C › Temperature range: – Fuel: –40°C up to +140°C in production (diesel) – 40°C up to + 900°C › Accuracy: +/–1°C (at 0°C) › Working temp. electron.: –40°C up to +145°C › Response time: Up to 3 s › Accuracy: –40°C up to +500°C: +/– 5°C >500°C: +/–1% Technical Information Technical Technical Information Technical › Output: SENT Interface Sensors & Actuators 136 Sensors & Actuators 137 Turbo Purge Valve Variable Compression Ratio (VCR) Actuator

The Turbo Purge Valve controls HC vapors from the BLDC Motor for variable canister to the turbo-charged intake manifold. compression ratio actuation.

› EVAP turbo system cost savings for OEM › High dynamics (low inertia) › Smooth start-to-open characteristics › Field-oriented, sinus, and block commutation Combustion Combustion Benefits Benefits › Robust design and easy to calibrate › Actuator size approx.: D 150 x 70 mm › Multiple turbo purge system function in one assembly › EC motor stator size: D 65 x 20 mm › Flexible configuration using common actuator › Nominal Torque: 1.7 Nm › Max. EC motor power: 400 W › Incorporates check valves to protect purge system › Stator Slots number: 12 › Operating voltage: 9 V up to 16 V (13.5 V optimal) › Rotor poles number: 10 › Operating temp.: –25°C up to +125°C Technical Information Technical › Operation mode: Field-oriented, sinus, and › Operating pressure: Up to 400 kPa block commutation › Frequency: 5 Hz up to 30 Hz › Phase nr. and connection: 3 Δ (10 Hz recommended) › Operating temperature: –40°C up to 140°C

Technical Information Technical › Purge flow: 110 SLPM (stator potting) Sensors & Actuators 138 139 Variable Turbine Geometry Actuator

Best performance for VTG adjustment to optimize functional application and reduce fuel consumption.

› Continuous adjustment of external application using rotating output shaft › Ideal for use in VTG applications Benefits › Permanent feedback signal (contactless) › Options: Default position, integrated electronic

› Max. external load without return function: 40 Ncm › Max. continuous holding torque without return function at 140°C: 65 Ncm Doing more. For Clean Power. › Response time: <150 ms at 120°C Powertrain › Operation temperature: –40°C up to +160°C Technical Information Technical Exhaust After-treatment Solutions 140 141 Exhaust After-treatment Solutions

A Clean Solution. Not everything your engine emits necessarily needs to be converted into emissions. Systematic thinking After-treatment is called for here as well. With the right combination of combustion, electrification and exhaust after- treatment, the strengths of all three elements can complement one another while compensating for each others’ weaknesses. An electrically heated catalytic converter in a hybrid, for instance, ensures that the emission clean- up is activated immediately after the cooled combustion engine starts again, even after the vehicle has been coasting without using its engine for quite some time. For exhaust after-treatment as well: Only the pooling of clean energy expertise – materials, processes, innovative designs and economical production – with sensor technology and actuators, the engine control unit and energy management system deliver the best results. It is a task that de- mands systems expertise. Continental Powertrain offers an optimal range of technologies as the groundwork for especially high- performance exhaust after-treatment – from catalytic converters and filters to SCR. A clean solution. Engine Systems 142 143 After-treatment Air-Cooled SCR Injector Control Module

Controller for Key technology in the area exhaust after-treatment systems (SCR, DPF). of NOX reduction to meet the future emission legislations.

› 12 V/ 24 V supply › Single fluid airless system

› Supports CAN based sensors (e.g. NOX, urea quality) › Simple and reliable delivery of urea with excellent spray performance Benefits › Chassis-mounted (under hood) Benefits › Multiple spray configurations › Core: Andorra › Spray patterns: Cone, bent, elliptical › Flash size: 4 MB › Sauter Mean Diameter (SMD): 70 μm up to 155 μm › Interfaces: 3 CAN dependent upon OD › Injector drivers: 3 urea or HC dosing › Fluid pressure range: 4 bar up to 9 bar › Driver outputs: 4 high-side + 19 low-side After-treatment › Max. body/ambient temp.: 160°C continuous › Tightness: IP5K6K › Max. tip fluid temperature: 120°C continuous Technical Information Technical › Connector pins: 62 with peaks to 130°C Technical Information Technical › Max. inlet temperature: 110°C continuous Engine Systems 144 145 Liquid-Cooled SCR Injector Urea Dosing Control Unit

Liquid-cooled SCR dosing unit for NOX reduction in close Standardized, validated electronic, and SW platform for coupled applications. NOX after-treatment control of passenger vehicles.

› Simple and reliable delivery of urea with excellent › Proven mechanical and electronic concepts spray performance (driver, ASICs etc.) › Multiple spray configurations › One or two chambers connector approach enables Benefits Benefits optimized wiring harness › Flexible design helps packaging in engine compartment environment › Direct connection to ECU and pump module › 12 V application › Spray patterns: Cone and elliptical › Core: Bolero › Sauter Mean Diameter (SMD): 60 μm up to 130 μm (5 bar) › Flash size: 1 MB › Fluid pressure range: 4 bar up to 6.5 bar › Interfaces: CAN, SENT, PWM After-treatment › Max. injector fluid tip temp.: 130°C peak › Injector drivers: High-/low-side › Heater driver: 2 + 1 optional › Max. ambient temperature: 200°C continuous › Pump driver: BLDC pump Technical Information Technical + optional transfer pump Technical Information Technical › Housing: Plastic housing; IPX6K9 Fuel & Exhaust Management 146 147 CS-Design LS-Design® (Crossversal Structure) (Longitudinal Structure)

New metallic substrate design to increase efficiency during Metal substrate cold start and warm up without penalty in backpressure. for catalytic converter.

› Material and cost saving due to elimination of flat foils › Further increased catalytic efficiency compared › GSA compensation by higher cell density of to standard structure, due to turbulence generating corrugated layer and improved mass transfer secondary corrugation Benefits Benefits › Improved coating distribution due to reduced › Significant performance improvement – alternative contact lines to higher cell density › Lower back pressure compared to equal efficiency › Less material, improved light-off-performance, standard substrate cost-effective

› Cross corrugated foils without flat foil layer › Metal substrate to be coated with various catalyst formulations for combustion engine exhaust

› Metal substrate to be coated with various catalyst emission control After-treatment formulations for combustion engine exhaust emission control › Application as three-way catalyst for gasoline engines as well as DOC, NOx-adsorber and SCR › Application as three-way catalyst for gasoline catalyst for diesel engines engines as well as DOC, NOx-adsorber, and SCR catalyst for diesel engines › Cell density from 100/200 cpsi up to 400/800 cpsi

› Variance of cell densities and foil thicknesses Information Technical › Foil thickness 40 up to 80 μm (1.6 up to 3.2 mil) Technical Information Technical for catalytic converter. catalytic for substrate Metal PE-Design® and LS-Design® Management Fuel &Exhaust Technical Information Benefits engines as well as DOC and SCR catalyst for diesel diesel for engines catalyst SCR and DOC as well as engines control emission exhaust engine combustion for formulations inlet catalyst at inhomogeneity concentration corrugation secondary generating turbulence to due substrates ceramic and structure, TS structure, › › › › › ›

Foil thickness 40 up to 80 μm (1.6 to μm up 80 40 mil) to up 3.2 Foil thickness cpsi to up 400/800 cpsi from density 100/200 Cell gasoline for catalyst three-way as Application catalyst various with coated to be substrate Metal or flow of case in improvement Performance standard to compared efficiency catalytic Increased 148 for catalytic converter. catalytic for substrate Metal (Mixing Structure) (Mixing MX-Design® Technical Information Benefits perforated flat foils flat perforated applications SCR in reductant injected control emission exhaust engine diesel for lation SCR-reaction for to ammonia conversion substrate the of downstream through pass than rather evaporate and wall catalytic › › › › › › › ›

Foil thickness 65 μm (2.6 mil) (2.6 65 μm Foil thickness cpsi 40 density Cell with combined corrugation shovel density cell Low for catalyst hydrolysis and evaporator as Application formu- hydrolysis with coated to be substrate Metal urea improves coating hydrolysis with MX formation deposit of risk eliminates / Reduces hit will droplets assure perforation and Shovels 149

After-treatment for catalytic converter. catalytic for substrate Metal Structure) (Perforated PE-Design® Management Fuel &Exhaust Technical Information Benefits gasoline engines gasoline control emission exhaust engine combustion for formulations inlet catalyst at concentration-inhomogeneity or homogenization flow by volume light weight › › › › › › › ›

Foil thickness 40 up to 80 μm (1.6 to μm up 80 40 Foil thickness mil) to up 3.2 from density 100 cpsi Cell to up 900 cpsi for catalyst three-way as special in Application catalyst various with coated to be substrate Metal flow- of case in improvement performance Significant catalyst of utilization better and backpressure Low performance light-off improved material, Less in results layer flat and corrugated of Perforation 150 for catalytic converter. catalytic for substrate Metal (TransversalStructure) TS-Design® Technical Information Benefits engines as well as DOC, NO DOC, as well as engines control emission exhaust engine combustion for formulations substrates ceramic and structure structure corrugation (TS-Design®) › › › › › › › › catalyst for diesel engines diesel for catalyst

Foil thickness 40 up to up 40 110Foil thickness (1.6 μm mil) to up 4.3 100 cpsi to from up 500 cpsi density Cell gasoline for catalyst three-way as Application catalyst various with coated to be substrate Metal space package Smaller Backpressure advantage standard to compared efficiency catalytic Increased transversal by performance conversion Improved X -adsorber, and SCR SCR and -adsorber, 151

After-treatment for catalytic converter. catalytic for substrate Metal Structure) (Standard Straight Channel METALIT® Management Fuel &Exhaust Technical Information Benefits engines as well as DOC, NO DOC, as well as engines control emission exhaust engine combustion for formulations substrates › › › › › › › › › catalyst for diesel engines diesel for catalyst

Foil thickness 25 to up Foil thickness 110 (1 μm mil) toup 4.3 to up 50 cpsi from density 1600 cpsi Cell gasoline for catalyst three-way as Application catalyst various with coated to be substrate Metal by welding system exhaust intothe canning Easy space package Smaller backpressure Lower performance cold-start Improved ceramic than area surface geometric Larger X -adsorber, and SCR SCR and -adsorber, 152 mal mass. Increase of the thermo-mechanical durability. thermo-mechanical the of Increase mass. mal ther- and costs weight, lower with catalysts for mantle Thin Catalyst Thin Wall and Lightweight Technical Information Benefits › › › › › › ›

Mantle material: material: Mantle 25 to up 101.5 mm range: length Typical substrate to30 up 93 mm range: diameter Typical substrate stiffness to increase surface Structured Faster light-off durability thermo-mechanical Increase weight substrate of Reduction 1.4509 153

After-treatment EMICAT®, based on a 32 bit microcontroller unit. a32 on microcontroller bit EMICAT®, based Catalyst Heated Electrically the for control Power Heated Catalyst (EMICAT®) Controller for Electrically Management Fuel &Exhaust Technical Information Benefits battery) and to ground circuit controller › › › › › › › › › › min eprtrs 4° pt 85°C to up + –40°C temperatures: Ambient class protection IP6K9K power, controlled PWM 10 frequency base Hz (24V), kW 2.5 (12V), kW 1.6 180 A(12 current: continuous Max. V), 140 A (24 V), Power: Electrical Voltage: design compatible EMC short (overcurrent, output protected Electrically CAN via tools development and Diagnostic ECU SCR with and communication for interface CAN 80 A(48V)80 (48V) kW 3.0 12/24 devel.) V in V(48 154 catalyst including a high effective support catalyst. support effective ahigh including catalyst heated Electrically Electrically Heated Catalyst Catalyst Heated Electrically EMICAT® Technical Information Benefits › › › › › › › › › › › › ›

Diameter: 50 mm up to up 264 50 mm mm W 500 toW up 4,000 Diameter: 1,000 toW up 7,200 48 at Power V: W W toW up 3,600 300 24 at Power V: at Power 12 V: 12 V V/48 V/24 voltage: Operation challenges RDE of Support energy recuperation of Use power heating lower for activation Intelligent SCR low-temperature Improved liquids of vaporization supports energy Additional reduction metal precious for Potential phases no-load during cooling catalyst Reduced time less in reached temperature off light Catalyst 155

After-treatment (HC), carbon monoxide (CO), and nitrogen oxides (NO oxides nitrogen and (CO), monoxide carbon hydrocarbon (HC), simultaneously reducing catalyst METALIT® Three-Way Catalyst (TWC) Management Fuel &Exhaust Technical Information Benefits customer requirements › › available › reduction for rhodium and oxidation › power maximum and › requirement › structure flow ›

Cell density and foil structure applicable to applicable structure foil and density Cell to up 450 mm diameter production Serial geometries non-round and round of variety Wide for rhodium and platinum with coating TWC consumption fuel optimum for Low backpressure space lower in results volume catalyst Reduced turbulent on based catalyst High-performance X 156 ). and carbon monoxide (CO). monoxide carbon and (HC) hydrocarbon Oxidizing (DOC) Diesel Oxidation Catalyst Technical Information Benefits › structure substrate generating › customer requirements › › available › palladium › › › compartment engine the in requirements space minimum

High-performance catalysts based on turbulence- on based catalysts High-performance Cell density and foil structure applicable to applicable structure foil and density Cell to up 450 mm diameter production Serial geometries non-round and round of variety Wide and platinum with coating catalyst Oxidizing design Robust consumption fuel optimum for Low backpressure for insulation gap air integrated with Possible 157

After-treatment Fuel & Exhaust Management 158 159 SCR Catalyst SCR Light-Off Catalyst

NOX reduction for all types of diesel engines in combina- Small catalyst slice on front of the SDPF improves the tion with Continental Ad Blue® dosing systems. system behaviour and the overall NOX reduction efficiency.

› High-performance reduction catalysts based on › SCR efficiency improvement in cold and transient turbulence-generating substrate structure operation › Reduced catalyst volume results in lower space › Short slice in front of the DPF to achieve low Benefits Benefits requirement thermal capacity › Low backpressure for optimum fuel consumption › Further reduction of thermal capacity by using › Ammonia slip catalyst as a very short disc in metal PE-Design® design › SCR-coating: Base metals (vanadium) or zeolites › Wide variety of round and non-round geometries available › Cell density and foil structure optimized to application After-treatment › Serial production diameter up to 450 mm › Typical SCR Light-Off Catalyst length between › Cell density and foil structure optimized to 20 and 50.8 mm application › New CS-Design as a perfect base

› Lowest slip catalyst length, down to 20 mm Information Technical Technical Information Technical Fuel & Exhaust Management 160 161 Exhaust After-treatment Close-Coupled After- System for Two-Wheeler treatment System Gasoline

Small catalysts which can be combined to an Three-way catalyst substrate efficient two-wheeler exhaust after-treatment system. for lowest emission gasoline cars.

› High-performance catalysts based on turbulent flow › Lowest emissions due to fast light-off in structure close-coupled position › Low backpressure for high power applications › “CompactCat” canning provides optimum exhaust Benefits Benefits Benefits gas temperature utilization › Robust design › Engine control response and accuracy optimized › Applicable for 2- and 3-wheelers by catalyst-integrated lambda-sensor (Lambdasondenkat™) › Wide variety of round and non-round geometries available › High-performance metal substrate with LS structure /LS-Design® › Very small diameters possible, Ø ≥ 30 mm › Close-coupled position directly at turbocharger After-treatment › Cell density and foil structure applicable to outlet customer requirements › “CompactCat” canning with hot gas circulating the catalyst surfaces › Same components utilized also in SULEV and Diesel Technical Information Technical engine applications Technical Information Technical Fuel & Exhaust Management 162 163 Close-Coupled After-treatment Compact System Light-Duty (LDD) Catalyst

Oxidation catalyst substrate Close-coupled mounted for lowest emission diesel cars. catalyst integrated in a reverse chamber flow.

› Lowest emissions due to fast light-off in › Highest inlet gas temperatures close-coupled position › High catalyst volume › “CompactCat” canning provides optimum exhaust Benefits Benefits Benefits › Low back pressure gas temperature utilization › Reduced heat capacity substrate › Optimum flow distribution to directly connected Diesel particulate filter › Complete outer insulation possible › High-performance metal substrate with LS-Design® › Close-coupled mounted catalyst › Close-coupled position directly at turbocharger › Catalyst insulated by exhaust gas

outlet After-treatment › Integrated functions: Sensor, heating (EMICAT®), › “CompactCat” canning with hot gas circulating the NH3 mixing without static mixer catalyst surfaces › Same components utilized also in SULEV and other Gasoline engine applications Information Technical Technical Information Technical Fuel & Exhaust Management 164 165 Compact SCR EHC System Sensor Catalyst Light Duty (LDD)

Oxidation catalyst in combination with electrical Catalyst with heated catalyst EMICAT® and reverse reductant injection. integrated hole for sensors.

› Lowest emissions due to fast light-off in close- › Optimization of space compartment coupled position › Protection of the sensors against water splash › Ammonia formation at lowest temperatures with Benefits Benefits Benefits › Direct and fast measuring in the catalyst to avoid EHC support breakthrough › Optimum flow distribution to directly connected SCR-coated diesel particulate filter › Temperature, NOX und Lamda sensors can be integrated in the METALIT® catalyst › Reverse reductant injection on hydrolysis coated › Combination with LS or PE structure is possible heating disc for flow uniformity

› High-performance metal substrate with After-treatment LS structure/LS-Design® › “CompactCat” canning with hot gas circulating the catalyst surfaces in close-coupled position Technical Information Technical › Electrical Heated Catalyst (EMICAT®)

Technical Information Technical for 12 up to 48 V/ 0.3 up to 4 kW System Heavy-Duty (HDD) After-treatment Close-Coupled Management Fuel &Exhaust advantages as already demonstrated in passenger cars. cars. passenger in demonstrated already shows as position advantages close-coupled in after-treatment Exhaust Technical Information Benefits decomposition enhancement decomposition rates conversion components SCR system exhaust whole the for as well use intra-urban at and cold-start › › › › › › › › › › Optional with EMICAT® for further low temperature temperature low further for EMICAT® with Optional size engine to the scalable design UDP DPF SCR-coated for Future-oriented highest and light-off fast for Optimization system total the of reduction Volume temperatures higher at injection (DEF) AdBlue® of front in Ammonia of homogenization Better temperatures higher at injection (DEF) AdBlue® as DOC for management thermal of Improvement at to improvement leads reduction loss Heat 166 Catalyst Heavy-Duty (HDD) Oxidation Close-Coupled exhaust temperatures for further decreased emission limits. emission decreased further for temperatures exhaust higher utilize can catalysts oxidation diesel Close-coupled Technical Information Benefits and geometrical shape geometrical and system exhaust whole the for as well use intra-urban at and cold-start freedom by design used › › › › › › › ›

Applicable even to existing vehicle concepts vehicle to even existing Applicable CRT and light-off fast for Optimization to up 30% reduction DOC-volume size of range wide a in substrate catalyst METALIT® temperatures higher at injection (DEF) AdBlue® as DOC for management thermal of Improvement at to improvement leads reduction loss Heat be can engine the around all space limited the Even 167

After-treatment Fuel & Exhaust Management 168 169 Universal Decomposition Ring-Shape DOC for Pipe (UDP) Advanced Compact SCR

In-pipe AdBlue® (DEF) injection and Urea decomposition Ring-shape Metalit® for DOC function in SCR systems with engineered in modular sizes for specific power ratings. integrated Urea decomposition feature in the center.

› Flexible in pipe installation › Inner hot tube with high droplet evaporation › Fast evaporation of AdBlue® (DEF) droplets capability due to intense turbulent gas flow › Usage of outer mantel design for flow guidance

Benefits › Integrated thermolysis of AdBlue® (DEF) droplets Benefits and hydrolysis to Ammonia (principle feature of CompactCat® design) › AdBlue® (DEF) dosing at low temperature duty cycles › Compact robust system build › Mixing of Ammonia with exhaust gas › Minimized thermal mass for low temperature AdBlue® (DEF) decomposition › Stainless steel housing with cockpit for SCR injector installation › Metallic substrate with high efficient foil structure

› Defined inlet geometry with confuser for flow › Scalable substrate with inner tube for flow guidance After-treatment guidance towards SDPF › Evaporator with coated METALIT® › Easy integration with customized mantel tube › METALIT® in MX-Design® with integrated shovels design for enhanced droplet evaporation

Technical Information Technical › Optional with electrically heated catalyst EMICAT® for

further low temperature decomposition enhancement Information Technical a ring shaped matrix, and an inner mantle. inner an and matrix, shaped a ring mantle, outer an of consisting catalyst shaped Ring Ring Catalyst Management Fuel &Exhaust Technical Information Benefits › › › › › › › › zone mixing turbulent to high due ›

Diameter inner mantle: mm to up 300 50 mm mantle: inner Diameter 100 cpsi to up 800 cpsi 130 mantle: to outer up 450 mm mm Diameter Foil design: to up mm 50.8 174 mm density: Cell length: Substrate design Compact aging Lower distribution flow on wastegate of influence Less distribution lambda cylinder single of Improvement LS; LS-PE; PE; PM PE; LS-PE; LS; 170 lysis pipe for highest NO highest for pipe lysis thermo- and mixing integrated with EMICAT® Ring-Shape Ring-Shape SCR EHC System Technical Information Benefits complete system complete › › › requirements › application on depending tube inner › › › environment hottest at agent reduction of decomposition capability, › ›

Ring-Shape EMICAT® with control unit as a as unit control with EMICAT® Ring-Shape ring-shape non-round and round in EMICAT® for EMICAT® 12, 24 48 and V application to according power heating of Variation and outer scalable with approach system Compact design system compact Very catalyst SCR for uniformity Ammonia Increased evaporation droplet high with tube hot Inner heating by electrical release dosing Earlier X reduction requirements. reduction 171

After-treatment Fuel & Exhaust Management 172 173 Particulate Matter Filter Exhaust Gas Recirculation PM-METALIT® Filter

Partial-flow deep-bed filter for particulate matter of diesel Lifetime EGR-filter with highest efficiency to protect turbo- engines with reduced maintenance demand. charger from ceramic particles due to DPF regeneration.

› Passive soot regeneration by NO2 in combination › Optimum engine dynamics with a DOC › Component protection for exhaust gas turbocharger › Active regeneration by engine measures or diesel and engine Benefits Benefits injection not required › Utilization for DPF OBD › Rapid regeneration in wide operating temperature › Replacement for soot sensor window › Usage of high efficient 2-layer TELA-wire mesh › PM-METALIT® filter to reduce particulate matter emissions › Evolvent weaving structure (GKD)

› Proven filter system to meet EU / China IV/ V, Tier 4i/f › Optimized filter efficiency After-treatment and similar exhaust emission regulations › High mechanical durability › Maintenance-free with appropriate engine fuel and oil specifications Technical Information Technical Technical Information Technical Fuel & Exhaust Management 174 175 Metallic Gasoline Air-Assisted Particle Filter Urea Dosing Unit UDA

Filtration at low pressure loss for application in gasoline Air-assisted AdBlue® (DEF) metering pump unit in combi- engines to meet future‘s particle emission legislation (RDE). nation with a passive working two-phase nozzle.

› Application as an add-on solution additional to a › Robust and proven frame mounted pump unit close coupled three-way-catalyst in uncoated › Low consumption of compressed air condition Benefits Benefits Benefits › Fine spray quality due to air-atomization of urea › Pressure drop significantly lower than comparable ceramic systems › Designed for heavy duty trucks, NRMM, and retrofit › Support of RDE challenges › Injection into high pressure exhaust (pre-turbo)

› High filtration efficiency of PM and PN › Pump Capacity: 7.5 l/h › Represents an ash tolerant solution › Operating pressure: nominal 3 bar up to 6 bar › Diameter range: 90 mm up to 150 mm › Integrated electronic control After-treatment › Length range: 50 mm up to 200 mm › Master, slave, and stand-alone modes › Specific filter › Compressed air control and mixing inside surface area: 0.4 m²/Liter › Precise urea metering by membrane pump Technical Information Technical Technical Information Technical Fuel & Exhaust Management 176 177 Tank-Integrated SCR Urea Tank-Integrated SCR Urea Extraction Unit Gen 4 Extraction Unit Gen III

Tank-integrated Tank-integrated urea urea extraction and pump unit ”Gen 4”. extraction and pump unit “Gen III”.

› Including filter, heating, level, and quality sensor › Including filter, heating, level, and quality sensor › Controlled pressure for stable spray pattern › Including integrated SCR dosing control unit (master, slave, stand alone), injector driver Benefits Benefits › Silent orbital pump with purge functionality Benefits › Maintenance-free lifetime filter › Reduced number of system components › Freeze proven › Freeze proven no-purged system › Welded directly into the tank › Robust piston pump, maintenance-free lifetime filter › Pump capacity: 2.7 l/h › CAN-connection to NOx- and Temperature sensors

› Operating pressure: 5 bar up to 5.5 bar (relative) › Pump capacity: 8 l/h After-treatment › Operating voltage: 12 V › Operating pressure: 5 bar up to 8 bar (relative) › Voltage: 12 V and 24 V Technical Information Technical Technical Information Technical Sensors & Actuators 178 179 Electrostatic Particulate Fluid Sensor – Urea Matter Sensor Concentration and Level

Sensor for On-Board Urea Concentration and Level Sensor helps to fulfill emis- Diagnosis of Diesel Particulate Filters. sion legislation and OBD requirements for SCR systems.

› High signal availability reduces calibration effort › Fast and accurate measurement of urea concentra- and enables high IUPR tion (AdBlue®/DEF) in the SCR system. › Reliable filter OBD ensured by activation of monitor- › Additional measurement of urea level and Benefits Benefits ing function only at robust conditions for sensor temperature and engine › Proven sensor technology › No effect of exhaust gas composites on the PM measurement signal (NO, NO2, O2, NH3) › Measuring principle: Ultrasonic › Output signal: CAN › Measuring range: 0 mg/m³ up to 25 mg/m³ › Measuring range: Concentration 0% up to 50% › Accuracy (ref. bench): ± 20% above 2.5 mg/m³ After-treatment › Urea mass above › Accuracy (ref. bench): ± 0.5 mg/m³ below 2.5 mg/m³ freezing point, level: 20 mm up to 500 mm › Gas temperature: Up to 950°C › Accuracy: Concentration ~2% urea mass › Data link: CAN 2.0 or SAE-J-1939 Technical Information Technical › Level: +/– 2 mm (up to 200 mm) › Measurement possible under inclination Technical Information Technical Sensors & Actuators 180 181 Mass Airflow Sensor Mass Airflow Sensor FMT MAF SENT FMT MAF+HPT SENT

Measures intake airflow and temperature for the engine Measurement of the intake airflow humidity, pressure, and management system with option for SENT interface. temperature for the engine management system.

› High flow measurement accuracy › High flow measurement accuracy › Integral protection against water and contamination › Integral protection against water and contamination Benefits Benefits Benefits › Excellent performance with intake airflow pulsation › Excellent performance with intake airflow pulsation › Enhanced EMC performance › Enhanced EMC performance › 3 pin device with SENT V4 interface › Options for humidity and pressure sensors

› Sensing technology: Next generation MEMS › Sensing technology: Next generation MEMS › Flow range: 4.5 kg/h up to 900 kg/h › Flow range: 4.5 kg/h up to 900 kg/h (62 mm tube) (62 mm tube) After-treatment › New-part tolerance: 1.3% › New-part tolerance: 1.3% › Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V › Supply current: 5 mA › Output signal: SENT V4 › Technical Information Technical Intake air temperature sensor optional Technical Information Technical › Output signal: Frequency or SENT V4 Sensors & Actuators 182 183 Mass Airflow Sensor Pressure Sensor – Particle MT MAF Filter/ EGR Differential

Measurement of the Differential measurement of exhaust treatment particle intake airflow for the engine management system. filter pressure drop / across EGR orifice.

› High flow measurement accuracy and signal stability › Flexible calibration of transfer functions › Integral protection against water and contamination › Precision programmable clip levels Benefits Benefits Benefits › Excellent performance with intake airflow pulsation › Internal and output diagnostic capability › Customer specific programmable output › High accuracy and temperature stability characteristic › Flexible housing, connector and mounting design

› Sensing technology: Hot-film bi-directional MEMS › Pressure range: –50 kPa up to +100 kPa › Flow range: 5 kg/h up to 800 kg/h (differential) (62 mm tube) › Accuracy: 1% full scale (10°C up to 85°C) After-treatment › New-part tolerance: 1.5% › Temperature range: –40°C up to +125°C › Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5V ± 0.5V › Supply current: 8 mA maximum › Supply current at 5 V: 10 mA max

Technical Information Technical › Output signal: Frequency Technical Information Technical › Load resistance: > 4.7 kOhms › Intake air temperature sensor optional › Output signal: Analog or SENT Sensors & Actuators 184 185 Pressure Sensor – Particle Pressure Sensor Filter Gauge (Single Port) Secondary Air Absolute

Relative measurement of exhaust pressure before Direct measurement of pressure in secondary air flow. or after the DPF.

› Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels › High accuracy and temperature stability

Benefits › Internal and output diagnostic capability Benefits › Low cost design and high quality › High accuracy and temperature stability › Fulfills toughest EMC requirements › Fulfills toughest EMC requirements › Flexible housing, connector, and mounting design

› Pressure range: 0 kPa up to 125 kPa › Pressure range: 50 kPa up to 150 kPa (for SAA) › Accuracy: 1% full scale (10°C up to 85°C) › Accuracy: 1% full scale (10°C up to 85°C) › Temperature range: –40°C up to +125°C › Temperature range: –40°C up to +140°C After-treatment › Supply voltage (Vs): 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V › Supply current at 5 V: 10 mA maximum › Supply current at 5 V: 10 mA maximum › Load resistance: > 4.7 kOhms › Load resistance: >4.7 kOhms Technical Information Technical › Response time: < 2 ms Information Technical Sensors & Actuators 186 187

Smart NOX Sensor Smart NOX Sensor Gen 4.0A Gen 4.0P

NOX measurement, upstream NOX measurement, or downstream SCR. Optimizes urea injection. upstream or downstream SCR. Optimizes urea injection.

› Real time high accuracy measurement › Real time high accuracy measurement › Sensor performance independent of catalyst › Sensor performance independent of catalyst or ECU supplier and engine management system or ECU supplier and engine management system Benefits Benefits

› Modular “Stand-alone” NOX sensor enabling › Modular “Stand-alone” NOX sensor enabling EU / US /Japan emission standards compliancy EU / US /Japan emission standards compliancy

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

› Triple output signal NOX, binary λ, linear λ › Triple output signal NOX, binary λ, linear λ

or O2-concentration or O2-concentration After-treatment › Supply voltage: 12 V or 24 V › Supply voltage: 12 V or 24 V › Data link: CAN 2.0 or SAE-J-1939 › Data link: CAN 2.0 › Operating gas temp.: 100°C up to 800°C › Operating gas temp.: 100°C up to 800°C Technical Information Technical Technical Information Technical Sensors & Actuators 188 189 Temperature Sensor Temperature Sensor EGR High Multiple

Temperature measurement in EGR system, EGR bypass Temperature acquisition for closed-loop after-treatment valve function diagnostic and thermal protection. control (DPF, SCR, DeNOX / LNT).

› Temperature measurement of EGR systems › Smart sensor with digital output, high accuracy › Connector design concept for temperatures › Stable signal over lifetime (ageing compensation) up to 450°C Benefits Benefits › High temperature robustness › Resistant to exhaust gases and other relevant › Fast response due to small thermal inertia chemicals at EGR applications › High resolution of temperature signal › Robust stainless steel cup › Thermocouple sensor technology, Type N › RTD or NTC sensor technology › Response time: 7 s at 10 m/s flow (4 s at 20 m/s) › Different Pt curves possible (Pt200, Pt1000) › Sensing temp.: –40°C up to +1,000°C After-treatment › Measuring tolerance: +/–7°C over lifetime › Working temp. electronics: –40°C up to +140°C › Response time (T63): <13 sec. at air speed 10 m/s › Accuracy: < 500°C +/– 5°C over lifetime › Temperature range: –40°C up to +450°C; > 500°C +/–1% over lifetime up to +600 °C (peak 60 sec.) Technical Information Technical › Supply voltage: 12 V or 24 V DC (30 mA) /CAN; Technical Information Technical 5 V DC (< 20 mA) / SENT Drivetrain Efficiency Solutions 190 191 Drivetrain Efficiency Solutions

Turning Force into Driving Comfort. Automatic transmissions can make a major contribu- tion to vehicle efficiency and to the overall driving Efficiency experience. The transmission creates the connection between the engine and the wheel. Therefore, a drive can only be as good as its transmission. The power transmission comfort and efficiency de- pend greatly on the transmission control unit. When does the vehicle change gears, and how quickly does it do so? How are vibrations dampened? When is the engine shut off? Is electric power integrated? Is it recuperated? How can force be trans- mitted to the wheels as efficiently and seamlessly as possible? Highly integrated controllers with mechanical components (hydraulics) are delivering ever in- creasing performance today, even in narrow installation spaces and in extremely hot and aggressive environments. Ten years and longer, 300,000 km and more. More and more compact solutions with new substrates, new manufacturing processes and new component generations are also creating space for the additional integration of electric motors into the transmission. This is how you turn force into driving comfort. Fuel & Exhaust Management 192 193 Electric Fuel Pump – EC Electric Fuel Pump – DC

Diesel Pump Diesel Pump Gasoline Pump Gasoline Pump

In-tank fuel pump with In-tank fuel pump brushless electronically commutated (EC) motor. with brush-type direct current (DC) motor.

› Improved quality, reliability, and durability (less parts, › Most cost-effective solution for non-electronically no commutation wear) regulated systems › Higher efficiency › Stand-alone (electronics not required) Benefits Benefits › Electromagnetic compatibilty › Gerotor and turbine pump principles › Body born noise reduction › Pressure: Up to 700 kPa › Gerotor and turbine pump principles › Flow, typ.: 230 l/h at 500 kPa › Pressure: Up to 700 kPa › Efficiency, typ.: 30% › Flow, typ.: 330 l/h at 500 kPa › Size: 28 mm, 38 mm, 43 mm › Efficiency, typ.: 35% › Media: Diesel (incl. RME),

Technical Information Technical Gasoline (up to E100) › Size: 38 mm, 43 mm, 50 mm

› Media: Diesel (incl. RME),

Technical Information Technical Gasoline (up to E100) Efficiency for Entry Level Vehicles Fuel Delivery Module Management Fuel &Exhaust gasoline module. gasoline referenced Flange Technical Information Benefits

› › › › › ›

Serviceable elements elements Serviceable valve vent Integrated weight Low module recreational vehicles and two-wheelers for applicable Also requirements flow low with tanks compact for Suitable flange integration high to due solution effective cost Very 194 mance module for diesel and gasoline. and diesel for module mance perfor- high referenced Bottom for High-End Applications Fuel Delivery Module Technical Information Benefits

› › › › › ›

Hydraulic performance: performance: Hydraulic pumps DC brushed-type or EC pumps Brushless Dual pump configurations solutions sensor level fuel and jet-pump Multiple geometries tank complex for Applicable vehicles performance high for Developed >280 l/h at 6.5 bar 6.5 at l/h >280 195

Efficiency Fuel & Exhaust Management 196 197 Fuel Delivery Module Fuel Level Sensor with an for Standard Applications Open Contact System

Bracket with Three Finger Contacts

In-tank Fuel Delivery Module for diesel and Cost effective sensor gasoline with the opportunity to integrate various functions. with open contact system.

› Cost effective modular design to cover various › Redundant contacts customer requirements › Various contact materials for different technical › Constant flow or demand regulated requirements and market specific fuel compositions Benefits Benefits

› Brushless EC pumps or brushed-type DC pumps › Measuring range: Angle up to 100° › Optional integrated: Fuel level sensor, filter, pressure › Operating current: 1 up to 20 mA regulator, electronics, vent valves, and tank leakage › Resolution: 1.25 degree /pad detection sensor › Max. resistor tolerance: +/–1% › Operating temperature: –40°C up to +80°C Technical Information Technical Technical Information Technical Efficiency a Sealed Contact System with Sensor Level Fuel fully capsulated sensor element. sensor capsulated fully a with Fuel LevelSensor Management Fuel &Exhaust Technical Information Benefits

› › › › › › › ›

temperature: Operating tolerance: resistor Max. Resolution: current: Operating range: Measuring compatibility Electromagnetic system measurement free wear a of because cycles) million (>10 time life Longer corrosion against protection robust assure contacts sealed Hermetically –40°C up to up +80°C –40°C +/–1% /pad 1.7 degree toUp 20 mA toUp 90° Tank Sensor Modular Right: Sensor) Position Passive (MAgnetic MAPPS Left: 198 Fuel Delivery Controller regulation of fuel delivery modules. delivery fuel of regulation demand for Electronics Technical Information Benefits › › › › › › › › ›

Degree of protection: protection: of Degree signal: /output input Control temperature: Operating power: Electrical voltage: Operating module fuel in integrated or device Stand-alone level noise and vibration Reduced lifetimeEnhanced energy consumption Reduced of electrical IP6K7 IP44and PWM to up +85°C –40°C 100 W to up 200 W 6 toV up 16 V 199

Efficiency Fuel & Exhaust Management 200 Sensors & Actuators 201 Tank Domain Controller Position Sensor Linear Contactless

Inductive Technology

Central controller to Sensor mainly used for park /no park, clutch master sensors and actuators in tank domain. cylinder, linear actuators, PRND, fork position sensor.

› Reduced consumption of electrical energy › Metallic target (Al, Fe, etc.), no magnet needed › Enhanced lifetime › Immune versus low frequency magnetic field (electric motor, starter current, etc.), no pollution by Benefits › Reduced vibration and noise level Benefits iron particles › Processing of other signals (e.g. fuel level sensor, › ASIC available pressure sensor, leakage detection) › Compliant with ISO 26262 (safety requirement) › Operating voltage: 6 V up to 16 V › Measuring range: 6 mm up to 60 mm › Electrical power: 100 W up to 200 W › Overall accuracy: +/–2% › Operating temperature: –40°C up to +85°C › Air gap: Up to 5 mm › Control input /output signal: CAN › Linearity: <+/–1% full scale › Degree of protection: IP6K7 and IP44 › Operating temp. range: –40°C up to +160°C › No hysteresis

Technical Information Technical ›

Technical Information Technical Output signal: Analog, PWM or SENT Efficiency › Flat or cylindrical shape targets Rotary Contactless Rotary PositionSensor &Actuators Sensors thermal management), general purpose rotary actuators. rotary purpose general management), thermal ETC, ACV, (EGR, valve, water position valve rotary For PRND, Technology Inductive Technical Information Benefits

› › › › › › › › › › › › ›

End of shaft or off axis configuration axis off or shaft of End signal: Output temp. range: Operating hysteresis No Linearity: gap: Air accuracy: Overall range: Measuring requirement) 26262 ISO with (safety Compliant available ASIC configuration redundant or Single particles by iron pollution no field, magnetic frequency low to Immune magnet no target, Metallic Analog, PWM or SENT or PWM Analog, to up +160°C –40°C scale full <+/–1% toUp 5mm +/–1% toUp 360° 202 Technology Effect Hall Rotary or Linear Contactless Sensor Position used for gear neutral, all gear sensors, CMC, pedal, etc. pedal, CMC, sensors, gear all neutral, gear for used Linear GPA. position, valve rotary PRND, for used Rotary Technical Information Benefits

› › › › › › › › › › › › ›

X-Y measurement possible X-Y measurement signal: Output voltage: Operating temp. range: Operating gap: Air measurement: Linear to Up 360° range: measuring Rotary Target: accuracy: Overall magnets ferrite with Compatible gap air High measurement wall aluminum Through size sensor Small Analog, PWM, SPI or SENT or SPI PWM, Analog, 0.5 V 5 V +/– to up +150°C –40°C toUp 11 mm to mm Up 60 magnet ferrite NdFeB, +/–2% Min. according to application according 203

Efficiency displacement pump to cover the hydraulic base load. load. base hydraulic to the cover pump displacement fixed efficient Small, Twin Drive Pump &Actuators Sensors Technical Information Benefits requirement sensor with/without pump main mode electrical and/or functions engine-off › › › › › › › ›

Vane-type pump Vane-type customer on depending commutation, BLDC ~150 W to W up 500 power: Electric motor BLDC commutated Electronically driven electrical and mechanical Combined modes operation both in efficiency overall Highest mechanical in separate or simultaneously Operates and loads peak cover to function boost Electrical 204 Cover Sensor Position Smart general purpose electrical actuators. electrical purpose general controlling for used Sensor Position Smart Technical Information Benefits (metal target, no magnet) no target, (metal › › › › › › › › › › › › ›

Built in protections: O/L, O/T, O/V, U/V O/L, interface PWM or LIN CAN, protections: in Built to Up 140°C temperature: Operating control PID embedded with MCU 16-bit hysteresis no +/–1%, capability current 4Amp with driver H-bridge configuration sensor off-axis or shaft of End accuracy: Sensor toUp 360° range: measuring Sensor operation temperature High control position for Microcontroller (ASIC) motor DC for driver H-bridge fields magnetic tofrequency low Immune ASIC with sensor position Inductive 205

Efficiency Transmission 206 207 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission

Integrated transmission control unit Integrated transmission control unit for wet 7-speed for dry 7-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).

› Mechatronic module integrated in the gearbox › Mechatronic module integrated in the gearbox › Direct connection of actuators to the control unit › Short links to sensor systems and actuating elements Benefits Benefits › Higher reliability of the electronics due to the reduced number of internal connections › Reduced harness length › Considerable weight reduction due to integration › Substrate: LTTC (Low temperature co-fired › Optimized driving comfort and fuel consumption ceramics) substrate for electronic components

› Substrate: Bare-Die High-Density Interconnect › Operating temperature: – 40°C up to +145°C › Operating temperature: – 40°C up to +140°C › 32-bit microcontroller › 32-bit microprocessor › Sensors: 4 gearshift position, 2 speed, 2 pressure, 1 temperature › Control of BLDC motor of oil pump › Actuators: 11 closed-loop controlled valves › Sensors: 4 gearshift position, 2 clutch position, Information Technical 2 speed, 1 pressure, 1 temperature Efficiency › Technical Information Technical Actuators (Control): 8 x PWM proportional solenoids Transmission 208 209 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission

Integrated transmission control unit Integrated transmission control unit for wet 7-speed for wet 7-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).

› Efficient design and packaging, reduced wiring, and › AWD applications, longitudinal installation of the weight engine › Short links to sensor systems and actuating elements › Fully integrated control unit contains all electronic Benefits Benefits components › Full integration of TCU, sensors, and solenoids › Improved shifting performance and comfort › For use in front, rear, all-wheel-drive, and hybrid applications › Substrate: Ceramic substrate technology › Substrate: Bare-Die High-Density Interconnect › Operating temperature: –40°C up to +145°C › Operating temperature: –40°C up to +148°C › 32-bit microcontroller › 2 x 32-bit microcontroller › Vibrations up to 20 g › Sensors: 2 temperature, 1 motor speed, › Sensors: Temperature, pressure, speed, 2 various external sensors gear position

› Actuators: Control of 9 solenoids (+ 1 optional) Information Technical › Actuators: 11 solenoids Efficiency

Technical Information Technical › Functional safety level ASIL D › Functional safety level: ASIL C Transmission 210 211 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission

Integrated transmission control unit for wet 7-speed Mechatronic actuator module for dry 6-speed Double Clutch Transmission (hydraulically controlled). Double Clutch Transmission.

› Integrated module directly mounted in transmission › Directly attached to the gearbox › Short links to sensor systems and actuating › Includes 2 BLDC motors elements Benefits Benefits › Higher reliability and accuracy of control › Small space requirements › Flexible transmission design in regards to package › Substrate: Thickfilm ceramic substrate technology › High dynamics of integrated gear shift actuators › Operating temperature: –40°C to +145°C › Substrate: PCB technology › 32-bit microcontroller › Operating temperature: –40°C up to +115°C › Sensors: 4 gearshift, 1 parking lock, 3 speed, › 32-bit microcontroller 2 temperature, 2 pressure › Sensors: 2 temperature, 2 shift motor position › Actuators (Control): 10 solenoids, 1 BLDC-motor › Actuators: 2 BLDC motors for gear changing for oil pump Technical Information Technical › Integrated control for 2 external BLDC motors for › Functional safety level: ASIL C

Technical Information Technical clutch control Efficiency › Functional safety level: ASIL C Transmission 212 213 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission

External transmission control unit for wet-clutch Universal transmission control unit for 7-speed 7-speed Double Clutch Transmission. Double Clutch Transmission for hybrid vehicles.

› Stand-alone module › Supports electromechanical actuation and smart actuators › Simple integration into vehicle › External module or directly mounted to transmission Benefits › Enables selection of different shifting characterístics Benefits › Improved shifting comfort › Substrate: PCB-FR4 › Operating temperature: –40°C to +105°C › Substrate: PCB technology › 32-bit microcontroller › Operating temperature: –40°C up to +85°C › Sensors: 2 x 3 hall sensors › 32-bit microcontroller › Actuator outputs: 2 drivers for EC motor, › Sensors: 3 pressure (analog), 2 HS driver function 2 temperature (analog), 4 position (PWM),

3 speed (frequency) Information Technical › Communication: CAN and LIN › Actuators: 9 solenoids (7 closed loop + 2 open loop) Technical Information Technical Efficiency Transmission. Clutch Double for platform unit control Transmission Double Clutch Transmission Control Unit for Transmission Technical Information Benefits › › › › › › › › ›

Control of BLDC motor BLDC of Control outputs toUp control current 12 closed-loop 32-bit microcontroller to up +125°C –40°C temperature: Operating PCB technology Substrate: cluster sensor integrated with use for Optimized solution optimized weight and Cost concepts attached-to or Stand-alone use flexible for unit control Platform 214 for wet 6-speed Double Clutch Transmission. Clutch Double 6-speed wet for unit control transmission Integrated Double Clutch Transmission Control Unit for Technical Information Benefits

› › › › › › › › › › ›

Functional safety level: ASIL C ASIL level: safety Functional prop. (4 + 9solenoids 5on/off) Actuators: 2 temperature, position, 4linear 2speed, Sensors: 32-bit microcontroller to up +140°C –40°C temperature: Operating Ceramic Substrate: comfort and performance shifting Improved processing signal / sensors Integrated to integration due reduction Weight body valve on mounted Directly gearbox the in integrated module Mechatronic 1 2speed direction, 2 pressure, 2 pressure, 1 range, transmission 215

Efficiency Transmission 216 217 Control Unit for Control Unit for Stepped Automatic Transmission Automatic Transmission

External transmission Integrated electro-hydraulic transmission control module control unit for 6-speed Automatic Transmission. for 6-speed Stepped Automatic Transmission.

› Compact module with small size and low weight › Integrated TCU including manifold and solenoids › Flexible mounting positions in engine or passenger › Compact module with small size and low weight compartment Benefits Benefits › Higher reliability and reduced number of connectors › Robust design with aluminum housing › Smooth shifting of gears › Substrate: PCB technology › Substrate: LTCC and FR4 technology › Operating temperature: –40°C up to +105°C › Operating temperature: –40°C up to +140°C › 32-bit microcontroller › 32-bit microcontroller with external flash memory › Communication: CAN › Actuators: 7 integrated solenoids › Safety level: ASIL B › Integrated hydraulic filter elements and manifold › Plastic mechatronic with integrated lead frames Technical Information Technical Technical Information Technical Efficiency Transmission 218 219 Control Unit for Stepped Control Unit for Stepped Automatic Transmission Automatic Transmission

Integrated control unit for 7-speed Stepped Automatic Transmission control unit for 5-speed Stepped Automatic Transmission. Transmission for rear-wheel drive vehicles.

› Mechatronic module › Mounted in engine compartment › Assembled on valve body of gear box › Simple integration into vehicle Benefits Benefits › Short links to sensors and actuating elements › Cost and weight optimized › Improved performance characteristics › Substrate: PCB technology › Substrate: Ceramic › Operating temperature: –40°C up to +140°C › Operating temperature: up to +140°C › 16-bit microcontroller › 32-bit microcontroller › Actuators: 2 control valves for hydraulic of transmission, 3 control valves for gearshift, 1 valve for › Sensors: 3 speed, 1 temperature, bypass converter 1 linear position (TRS) › Power output for 6 electro-mechanical › Actuators: 8 power outputs for solenoids Information Technical hydraulic valves Technical Information Technical Efficiency for 6-speed Stepped Automatic Transmission. Automatic Stepped 6-speed for unit control Stand-alone AutomaticTransmission Stepped for Unit Control Transmission Technical Information Benefits gear changes gear compartment › › › › › › › ›

2 power supply outlets for solenoids for outlets supply 2 power CAN Communication: 32-bit microcontroller to up +105°C –40°C temperature: Operating PCB technology Substrate: smooth and perfomance shifting Improved passenger or engine positions, mounting Flexible weight low size and small with module Compact 220 control unit for Continously Variable Transmission (CVT). Transmission Variable Continously for unit control transmission External ouslyVariable Transmission Control Unit for Continu- Technical Information Benefits 3 speed, 2 pressure, 2pressure, 1 3speed, temperature memory flash technology compartment › › › › › › › › ›

Actuators: 6 PWM proportional solenoid proportional 6PWM Actuators: control, gearlever 3 position, gearshift 5 Sensors: external with microcontroller 32-bit to up +95°C –40°C temperature: Operating technology PCB Substrate: platform to due time-to-market Reduced concept Stand-alone engine or passenger in placed module External Closed-loop controlClosed-loop 221

Efficiency Transmission 222 223 Universal Universal Transmission Transmission Control Unit Control Unit Platform

Universal transmission Universal transmission control unit platform for DCT, CVT, control unit for different types of transmissions. AMT, and Step-AT transmissions.

› Stand-alone TCU, chassis-mounted › External module placed in passenger or engine compartment › Flexible module with various inputs and actuator outputs › Stand-alone concept Benefits Benefits › Universal use for different types of transmissions › Cost and weight optimized (AT, CVT, AMT, etc.) › Reduced time-to-market due to platform technology › Substrate: PCB technology › Substrate: PCB technology › Operating temperature: –40°C up to +105°C › Operating temperature: –40°C up to +95°C › 32-bit microcontroller › 32-bit microcontroller with internal flash memory › Sensors: No sensor integrated in TCU › Sensors: 4 speed, 4 gear lever position, › Actuators: 10 PWM proportional controlled 2 pressure, 4 gear shift position, 2 temperature solenoids › Actuators: 8 PWM proportional solenoid controls Technical Information Technical

Technical Information Technical › Closed-loop control Efficiency › BLDC motor control Transmission 224 225 Electronic Control Unit Universal Control Unit for for Limited Slip Coupling Powertrain Applications

Control unit for limited slip coupling and AWD Universal control unit (CU) applications. for brushless DC (BLDC) motors.

› Unit directly attached to 4WD transfer case › CU can be used as a controller for e-clutch or e-axis actuators, as well as for electronic central shifter for › Control of valve and feeder pump to change hybrid modules torque distribution between front and rear axle Benefits Benefits › Stand alone module › Substrate: PCB technology › Compact and lightweight design › Operating temperature: –40°C up to +120°C › Substrate: PCB-FR4 technology › 16-bit microcontroller › Operating temperature: –40°C up to +125°C › Sensors: 1 pressure sensor, 1 oil temperature sensor › 32-bit microcontroller › Actuators (Control): PWM control of 2 proportional valves, 1 feeder pump motor › Sensors: 2 x 3 hall sensors (external)

Technical Information Technical › Actuators: 1 B6 driver for EC-motor (external) › Communication: CAN Technical Information Technical Efficiency Transmission 226 227 Transfer Case Multi Position Actuator Linear Actuator

4WD/AWD control unit with integrated motor for Control unit for an wet transfer cases. axle disconnect actuator.

› Directly attached to the transfer case › Mounted on Power Transfer Unit (PTU) on the axle › Integration of ECU, brushless DC motor, and sensors › Covers heat stake interface to PCB in one mechatronic actuator unit Benefits Benefits › Motor terminal blades on PCB › Substrate: PCB technology › Substrate: FR4 › Operating temperature: –40°C up to +140°C › Operating temperature: –40°C up to +125°C (Transfer Case) › 16-bit microcontroller › 16-bit microcontroller › Sensors: 8 linear hall effect, 1 rotational encoder, › Sensors: 1 angle position sensor 1 temperature › Actuators: 1 integrated BLDC-Motor › Actuators: Control of 1 brushed DC motor Technical Information Technical Technical Information Technical Efficiency Transmission 228 229 Direct Shift Module Sensorcluster for Wet Double Clutch Transmissions

Shift-by-Wire Actuator Transmission-integrated sensorcluster for Double Clutch for the PRND lever of an automatic transmission. Transmission.

› Shift-by-Wire module attached outside of the › Internal module mounted in the transmission gearbox › Can be used as stand-alone (with various TCUs) › Module is compact in size compared to coventional Benefits Benefits › Cost and weight optimized solution PRND shift-levers. This creates more space for other CUs › Operating temperature: –40°C up to +150°C › Substrate: PCB technology › Sensors: 4 gearshift position, 2 speed, 1 temperature › Operating temperature: –40°C up to +120°C (peak 140°C) › Provides sensor signals for the TCU › 16-bit microcontroller › Sensors: Lever angle, temperature, eccentric shaft

› Actuators: 2 motors for PRND shift and emergency Information Technical shift to P Technical Information Technical › Communication via CAN Efficiency Transmission 230 231 Smart Actuator Platform Control Unit for Automated Manual Transmission (CV)

Modular platform for peripheral devices for transmissions. External transmission control unit for Automated Manual Transmission for light /medium duty commercial vehicles.

› SmAP can be designed as a clutch actuator, a pump › External control unit, transmission-mounted for transmission lubrication or transmission cooling › Robust design, high reliability › Flexible actuation platform for transmissions Benefits Benefits › Reduced time to market due to standardised › Substrate: Flex FR4 PCB components › Operating temperature: –40°C up to +105°C › Supports electrification strategy of powertrains › 32-bit microcontroller › Voltage rating: 4.5 V up to 24 V › Sensors: 3 position, 3 speed › Power: 80 W up to 500 W › Actuators: 4 electric motors › Operating temperature: –40°C up to +140°C › Communication: CAN › Sensor or sensorless control Information Technical › Functional safety level: up to ASIL C Efficiency Technical Information Technical Transmission control unit for wet 7-speed Double Clutch Clutch vehicles. commercial duty medium for Transmission Double 7-speed wet for unit control Transmission Clutch Transmission (CV) Double for Unit Control Transmission Technical Information Benefits

› › › › › › › ›

– cooling oil pressure oil – cooling pressure oil – main valves – 2safety positions and – 4gearshifts of: Control RAM of 4mb with 32-bit microprocessor to up +125°C –40°C temperature: Operating strategies shifting gear efficient Supports assist hill-start and mode creep Supports harness wiring the of length and complexity Reduced Substrate: PCB technology PCB Substrate: vehicles commercial duty medium for unit control External 232 actuator for commercial vehicles. commercial for actuator clutch Electronic and Off-Highway)(CV Electronic Clutch Actuator Technical Information Benefits › › › › › › ›

Refined clutch actuation, enables creep mode creep enables actuation, clutch Refined ms 250 within 17° angle stability thermal High to up 50 G) shock: (mechanical design Rugged

General: Motor: Electronics:

– – – – – – – – – –

Integrated position sensor position Integrated set gear planetary 100:1 at Nm 2.5 1000 torque RPM 1200 RPM communication CAN 32-bit microcontroller 12 V/24 V Operating temp.: –40°C up to up +121°C –40°C temp.: Operating technology PCB Substrate: 250 W 3-phase BLDC motor motor BLDC 3-phase W 250 233

Efficiency www.continental-automotive.com 0 49 941 - + Phone 790 ·Germany 93055 Regensburg 12Siemensstrasse Division Powertrain GmbH Automotive Continental © Continental Automotive GmbH Automotive © Continental notice. prior without changes technical as well as availability in changes to make right the reserve We contract. of terms the in agreed expressly if exist only shall characteristics tive respec the to provide obligation An durability. guarantee for a particular quality or particular special a be to intended or meant not is mation infor This product. the of description technical a merely is information This products. the of development further of result a as change may which or use actual of case in described as apply always not do which characteristics, performance or descriptions general only tains con brochure this in provided information The Legal notice

- - -

Printed in Germany · 09/2017 · EN · 3.5 k · Order no.: 46-03-0104EN