Shanghai/China, October 15, 2010. Continental is actively engaged in integrating innovative and efficient system solutions affecting every aspect of the drive train in vehicles of all classes. In view of the China’s commitment, made last November, to reducing carbon dioxide emissions per unit of GDP by 40-45% by the year 2020, compared with 2005 levels, Continental’s Powertrain Division, one of the six divisions of the international autmotive supplier, is working on making driving more affordable and environmentally acceptable while enhancing driving pleasure and comfort for drivers.

By combining its innovative strengths with its systems and manufacturing expertise in state-of-the-art drive technology, the Powertrain Division offers a range of products which can effectively reduce emissions, optimize fuel consumption as well as achieve outstanding handling with the balance of quality and reliability. The Division’s expanded development and system know-how gives it a broad base and places it among the world’s top three. With sales of about 3.4 billion Euro in 2009, the Division is an active global player in every market. The Powertrain Division, is divided into five business units, including Engine Systems, Transmission, Hybrid Electric Vehicle, Sensors & Actuators and Fuel Supply.

More power and lower fuel consumption

Engine Systems Business Unit focuses on development and production of innovative system solutions for reliable, environmentally friendly and advanced combustion engines. The EASY-U is a ready-to-use gasoline Engine Management System (EMS) for the entry-segment and to the Chinese market requirements. In order to meet the demand of cost-effective, validated engine management and the ability to cope with various emission requirements – from Euro 3 to Euro 5 and above, Continental developed the Easy-U which was immediately recognized by the market. In China, Malaysia and India, the Easy-U is already a market leader. The Easy-U can control most 2 to 4 cylinders port injection engines, from the basic to the most sophisticated ones (double VVT, Turbo, EGR, etc). The Easy-U accepts very different car configurations – wired or CAN-connected dashboard, mechanical or drive-by-wire throttle body. It is meant to ease the transition of emerging markets OEMs from classical car architectures to state-of-the art architecture, including modern fuel saving features such as stop/start. With reduced size and weight, the Easy-U also fits easily under the hood or in the passenger cabin.

Globalization of transmission control units

Transmission Business Unit develops and produces electronics for controlling the latest automatic transmissions such as step-automatic transmissions, Continuously Variable Transmissions (CVT), Automated Manual Transmissions (AMT), Double-Clutch Transmissions (DCT), transfer boxes and all-wheel drive systems. The product portfolio ranges from external stand-alone control units to attached control units and mechatronics, which are fully integrated into the transmission.

The company successfully realized the important localization step that allows to support efficiently local manufacturers with its new Transmission Control Unit (TCU) platform, the so-called EAST platform developed locally. This modular and affordable system with 32-bit architecture is ideal for control solutions in all types of Automatic Transmissions (AT), from the traditional step-automatic transmissions to Double-Clutch Transmissions (DCT) and Automated Manual Transmissions (AMT) to automatic Continuously Variable Transmissions (CVT). On the one hand, the EAST platform uses the best features of current control unit technology but also makes the technology particularly economical by consistent exploitation of the platform principle in a stand-alone TCU.

Systems know-how for electromobility

The Hybrid & Electric Vehicles Business Unit emphasizes systems and components for hybrid and electric vehicles because of the projected fuel savings of 25% and extra boost of torque. As the first European supplier, Continental has been manufacturing production version hybrid systems since 2003 and can now provide a modular system which contains all the electrical components for both hybrid and electric drive systems.

To ensure the quickest possible market penetration of this eco-friendly technology, this business unit has developed low-cost, production-ready drive components and complete systems for electrifying the drive train. The core components are the energy storage unit (i.e. the battery), the power electronics and the electric motor. As hybrid and electric drive technology is gaining importance in China and other emerging markets, Continental has begun production of its EPF1 series of power electronics and is now developing the second generation power electronics EPF2 with its established customers for use in hybrid and electric vehicles. Through innovative design and packaging Continental was able to achieve approximately 30 percent less space than its predecessor and making it significantly easier to install in the vehicle; it is also more cost-effective to produce. The main tasks of the power electronics include converting the high voltage direct current from the battery into alternating current for the electric motor and to lower voltage direct current used for the controller and all other vehicle electric accessories.

Smart optimisation of fuel consumption

Without exception, every future drive train component and system - from new combustion techniques via exhaust-gas after-treatment to hybrid drives - will be electronically controlled. Consequently, particular importance attaches to sensors and actuators, which help reduce emissions and lower fuel consumption even further while improving performance. These crucial components extend service life and enhance comfort and safety, the overall target of the Sensors & Actuators Business Unit.

Continental earned the 2010 Automotive News PACE (Premier Automotive Suppliers Contribution to Excellence) Award for its Smart NOx Sensor for gas and diesel powertrains in the Product-Europe category. The Smart NOX Sensor is a ceramic sensor with customized micro electronics that help to communicate with the vehicle control bus to enable optimum adjustment of key engine parameters, such as exhaust gas recirculation, the air/fuel ratio and urea injection for SCR systems in order to reduce nitric oxide (NOx) emissions. In gasoline vehicles, the sensor is used in combination with lean-burn technology to control the regeneration cycle of the NOx storage catalyst. In diesel passenger cars and light trucks, it is used in conjunction with the exhaust after-treatment such as for Selective Catalytic Reduction (SCR) and NOx Storage Catalyst (NSC). In heavy-duty trucks, it is used for SCR as well.

Another sensor innovation is T-MAP (Manifold Absolute Pressure and Temperature Sensor) & Turbo T-MAP, the pressure sensors, measure the intake air pressure and temperature in order to determine the intake airflow, which is required to calculate the quantity of fuel to be injected and hence optimize the air-fuel ratio.

In addition, for gasoline engines, the Mass Airflow (MAF) Sensor measurements, combined with other sensor measurements, are used to adjust the amount of fuel injected into the engine. For diesel engines, the MAF sensor helps to control the exhaust gas recirculation (EGR) rate. Moreover, the MAF sensor provides information for system diagnosis.

As a reliable local partner in China, the local R&D and production teams of the Powertrain Division are working very closely together to provide highly reliable and high-performance sensors in order to meet the increasing demand from the local customers.

Save fuel with on-demand pumps

Continental is exploiting further potential for efficiency by using on-demand fuel pumps. Unlike the standard pumps currently used, they only feed the engine with just the amount of fuel it really needs. This intelligent principle saves between 60 and 70 percent of electrical energy compared with traditional constant fuel supply systems. In addition, using a pump control system can, as a rule of thumb, reduce CO2 emissions from a classical 1.8l engine by 1.5 to 2g of CO2 per kilometer. The control electronics open up further potential benefits for OEMs and drivers through lowering costs at the system level and improving the reliability of fuel feed systems, enhancing economic efficiency and comfort for customers, as well as playing a part in contributing to environmental sustainability in China.

Continental realizes on-demand fuel pump control in different ways depending on the customer's requirements. Essentially, all pump motors can benefit from on-demand control because Continental has opted for graduated modularity. Modularity plays a similarly major role in integral fuel feed units. Since today's fuel tanks come in the widest possible variety of shapes, Continental’s tradition of fuel tank system know-how has helped to conquer the challenge with a modular system which ensures standardization below the flange, covering 70 to 80 percent of all applications - at no extra cost.

Furthermore, systematic exploitation of the pump's control electronics is paving the way for additional benefits. One example is the option of moving to wear-free sensors for measuring the fuel level in the tank. A further important possibility is for the on-board diagnostics (OBD II) to detect fuel tank leaks.

With sales of approximately €20 billion in 2009, Continental is among the leading automotive suppliers worldwide. As a supplier of brake systems, systems and components for powertrains and chassis, instrumentation, infotainment solutions, vehicle electronics, tires and technical elastomers, Continental contributes enhanced driving safety and global climate protection. Continental is also a competent partner in networked automobile communication. Continental currently employs approximately 143,000 in 46 countries.

The Automotive Group with its three divisions Chassis & Safety (sales of approximately €4.4 billion in 2009, 27,000 employees), Powertrain (sales of approximately €3.4 billion in 2009, 24,000 employees) and Interior (sales of approximately €4.4 billion in 2009, 27,000 employees) achieved sales of approximately €12 billion in 2009. The Automotive Group is present in more than 130 locations worldwide. As a partner of the automotive and commercial vehicle industry, it develops and produces innovative products and systems for a modern automotive future, in which cars provide individual mobility and driving pleasure consistent with driving safety, environmental responsibility and cost-efficiency.

The Chassis & Safety Division develops and produces electronic and hydraulic brake and chassis control systems, sensors, driver assistance systems, airbag electronics and-sensorics, washer systems and electronic air suspension systems. Its core competence is the integration of active and passive driving safety into ContiGuard®. The Powertrain Division integrates innovative and efficient system solutions for vehicle powertrains. The comprehensive range of products includes gasoline and diesel injection systems, engine management, transmission control, including sensors and actuators, as well as fuel-supply systems and components and systems for hybrid and electric drives. Information management is at the very heart of the Interior Division, which provides a range of products that includes instrument clusters and multifunctional displays, control units, electronic car-entry systems, tire-monitoring systems, radios, multimedia and navigation systems, climate control systems, telematics solutions and cockpit modules and systems.

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