Usp Booklet

Powertrain Products
Benefits and Technical Information
Powertrain Products
Our road to sustainable mobility

The Powertrain Division integrates innovative and efficient system solutions for vehicle powertrains within the automotive supplier Continental AG. These systems increase performance and driving comfort while at the same time lowering consumption and emissions. As a partner of the automotive industry, the division develops and produces a comprehensive range of products at more than 60 sites around the world. These include gasoline and diesel injection systems, engine management, transmission control units including sensors & actuators and fuel supply systems as well as components and systems for hybrid and electric drives.
Product Applications
Passenger Car Application Light Duty Commercial Vehicles Application Medium / Heavy Duty Commercial Vehicles Application Two-wheel Application Agricultural Engines
Content
8 System Overview
8 Gasoline Piezo Stratified Turbo Direct Injection System 10 Gasoline Solenoid Turbo Direct Injection System 12 Gasoline Port Injection System Flex Fuel 14 Diesel Piezo Common Rail Injection System
16 Engine Systems ES
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 ECU Gasoline Solenoid Direct Injection ECU Gasoline Solenoid Direct Injection NAFTA ECU Gasoline & TCU Solenoid Direct Injection EMS 3 Engine Management System Platform ECU Gasoline Port Injection ECU Gasoline Easy-U Port Injection ECU Diesel Piezo Common Rail ECU for Light Duty Engines (Emerging Markets) ECU Platform for Commercial Vehicles ECU Diesel Heavy Duty Engines ECU Aftertreatment Control Gasoline High Pressure 1-Piston Pump Diesel High Pressure 1-Piston Pump Diesel High Pressure 3-Piston Pump Gasoline Piezo Injector Gasoline DI XL2 Solenoid Injector Gasoline DI XL3 Solenoid Injector Gasoline Deka VII Fuel Injector Diesel Piezo Common Rail (PCR) Injector Diesel PCR New Generation Injector Deka SCR Injector Deka Injector for Diesel Dosing into Exhaust Gas Gasoline Turbocharger
Powertrain Products
Content
42 Hybrid Electric Vehicle HEV
44 45 46 47 48 49 Power Electronics Modular Li-Ion Energy Storage System High Voltage Axle Drive System High Voltage Side-Mounted Starter Generator Motor Control Unit for Hybrid/Electric Vehicles 14 V Modular Power Net System
70 Sensors & Actuators S & A 72 72 73 74 75 76 77 78 79

80 81 82 83 84 85 86 87 88 89 90 91 92 93
50 Transmission TR
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Control Unit for Double Clutch Transmission Control Unit for Double Clutch Transmission Control Unit for Double Clutch Transmission Control Unit for Double Clutch Transmission Control Unit for Double Clutch Transmission Control Unit for Double Clutch Transmission Control Unit for Stepped Automatic Transmission Control Unit for Stepped Automatic Transmission Control Unit for Stepped Automatic Transmission Control Unit for Stepped Automatic Transmission Control Unit for Stepped Automatic Transmission ECU for Continuously Variable Transmission EAST Transmission Control Unit Control Unit for Transfer Case Control Unit for Limited Slip Coupling Transmission Control Unit for CV Automatic Transmission Control Unit for CV Transmission and Retarder Control Unit
Actuators Air Control Valve (ACV-S) Economy Line Air Control Valve (ACV-S) Performance Line Air Control Valve (ACV-S) MD/HD CV Line Air Control Valve (Smart ACV ) Brushless DC Drives High Efficiency Canister Purge Solenoid (CPS) Canister Purge Solenoid (CPS) High Flow Digital Linear Actuator for Idle Control Valve Generation I Digital Linear Actuator for Idle Control Valve Generation V Electric EGR (EEGR) Electronic Throttle Control (ETC) Economy Line Electronic Throttle Control (ETC) Perform. Line Exhaust By-pass Valve (EBV) Exhaust Control Valve High Pressure Exhaust Control Valve Low Pressure Exhaust Throttle Valve (ETV) General Purpose Actuator (GPA) Linear Purge Valve (LPV) Pump (EWP) Electrical Water Pump Pump (SCP) Smart Coolant Pump Pump (TOP) Transmission Oil Pump Variable Lift Control Actuator (Brushless DC) Sensors Door Handle Sensor Fluid Level Oil Level Switch Fluid Level Sensor Capacitive QLT Fluid Level Sensor Ultrasonic
94 94 95 96 97
Powertrain Products
Content
Sensors & Actuators S & A
98 99 100 101 102 103 104 105 106 107 107 108 109 110 111 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 Fluid Level Sensor Passive Electrothermic Fluid Quality Flex Fuel Sensor Fluid Quality Flex Fuel Sensor, High Integrated Fluid Quality Fuel Quality Sensor Hydrocarbon Sensor In-Cylinder Pressure Sensor Knock Sensor Wide Band Mass Airflow Sensor Natural Vacuum Leak Detection (NVLD II) Position Sensors: Linear Contactless (Hall Effect Technology) Linear Contactless (Inductive Technology) Rotary Contactless (Inductive Technology) Rotary Contactless (Magneto-Resistive Techn.) Pressure Sensors: Fuel High Pressure (GDI and DDI) Low Press. Brake Booster Absolute (BBA) Low Press. Absolute (MAP, TMAP BAP) , Low Press. Secondary Air Absolute (SAA) Low Press. Differential, Brake Booster Gauge Low Press. Differential, Filter Control Gauge Low Press. Differential, Manifold Gauge Low Press. Particulate Filter Differential Low Press. Differential, Particulate Filter Gauge Smart NOx Sensor Smart Particulate Matter (PM) Sensor Temperature Sensor Coolant/Fuel/Oil Temperature Sensor High Temperature Temperature Sensor Intake Air Temperature Sensor EGR Temperature Sensor Outside Air
128 Fuel Supply FS

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

138 140 141 142 143 144 145 146 147 148 148 149 150 151 Emitec: A brief company profile METALIT (3-Way-Cat) NOx-Adsorber Pre Turbo METALIT TM Compact Cat PM-METALIT SCRi -System LS-Design PE-Design Selective Catalytic Reduction SCR: Tank-integrated Dosing System Air Assisted Dosing System Airless Dosing System Digital Dosing System
System Overview 1 2 3 4 5 6 2 7 8 9 10 11 12 13
Gasoline Piezo Stratified Turbo Direct Injection System

24 25 26 27 28 29 30
No. Technology 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Single Coil Ignition Dual Variable Camphaser Active Camshaft Position Sensor Natural Vacuum Leak Detection (NVLD II) Hydrocarbon Sensor for Canister Purge Canister Purge Solenoid Low Pressure Fuel Pump (Demand Contr.) Gasoline High Pressure Pump Fuel High Pressure Sensor Fluid Ultrasonic Level Sensor Coolant (Water) Temperature Sensor Knock Sensor Active Crankshaft Position Sensor (also with Direction Detection) Linear O2 Sensor 3-Way Catalyst Binary O2 Sensor High Temperature Sensor Deka SCR Injector with Heated Pipes SCR Catalyst Smart NOX Sensor 9
14 15
16 17
18 19
20 21 22 23
No. Technology 1 2 3 4 5 6 17 8 9 10 8 Mass Airflow Sensor with integrated Temperature Sensor (Frequency Output) Electric Exhaust Gas Recirculation Valve Turbo Speed Sensor (Optional) Turbocharger with Electrical Wastegate Manifold Absolute Low Pressure Sensor Electronic Throttle Control Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor Exhaust Bypass Valve Gasoline DI Piezo Injector In-Cylinder Pressure Sensor (Optional f. CAI)
System Overview 1 2 3
Gasoline Solenoid Turbo Direct Injection System Euro 6

20 21 22
4 5 6 19 18
7 No. Technology 1 2 3 4 5 6 7 8 9 10 11 10
10 No. Technology 12 13 14 15 16 17 18 19 20 21 22
11 12 13 14 15 16 17
Turbocharger Manifold Absolute Low Pressure Sensor Electronic Throttle Control Canister Purge Solenoid Flex Fuel Sensor (Optional) Natural Vacuum Leak Detection (NVLD II) Fuel Supply Unit Gasoline High Pressure Pump Fuel High Pressure Sensor Fluid Ultrasonic Level Sensor Active Crankshaft Position Sensor (also with Direction Detection)
Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor Variable Lift Control Actuator and Sensor Knock Sensor Coolant (Water) Temperature Sensor Gasoline DI Solenoid Injector Single Coil Ignition Dual Variable Camphaser Active Camshaft Position Sensor Linear O2 Sensor 3-Way Catalyst Binary O2 Sensor
11
System Overview
Gasoline Port Injection System Flex Fuel

14
13
10 11 12
No. Technology 1 2 3 4 5 6 Canister Purge Solenoid Fuel Supply Unit Flex Fuel Sensor (Optional) Electronic Throttle Control Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor Gasoline Multipoint Injector (Heated Injector Optional)
No. Technology 7 8 9 10 11 12 13 14 Active Crankshaft Position Sensor (also with Direction Detection) Knock Sensor Coolant (Water) Temperature Sensor Ignition Coil Dual Variable Camphaser Active Camshaft Position Sensor 3-Way Catalyst Binary O2 Sensor 13
12
System Overview 1 2 3 4 5 6 7 8 9 10
Diesel Piezo Common Rail Injection System
Oxidation Catalyst
Diesel Particulate Filter
SCR
17 18
19 20
21 18
18 22 23 24
No. Technology 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 In-Cylinder Pressure Sensor (Optional) Fuel Supply Unit Diesel High Pressure Pump Fuel High Pressure Sensor Engine Coolant or Cylinder Head Temperature Sensor Active Crankshaft Position Sensor (also with Direction Detection) Fluid Ultrasonic Level Sensor General Purpose Actuator High Temperature Sensor Linear O2 Sensor Deka Diesel Dosing Injector (Optional) Low Pressure Differential Sensor Soot Sensor Deka SCR Injector with Heated Pipes Smart NOX Sensor 15
11 12 13 14 No. Technology 1 2 3 4 5 6 7 8 9 14
15 16
Mass Airflow Sensor Air Control Valve Exhaust Control Valve Low Pressure Turbocharger with Turbo Speed Sensor Exhaust Bypass Valve Manifold Absolute Low Pressure Sensor with integrated Temperature Sensor Active Camshaft Position Sensor Variable Camphaser Diesel Piezo Common Rail Injector
Engine Systems ES
16
ES
17
Engine Systems
ES
Engine Systems ES
ECU Gasoline Solenoid Direct Injection
ECU Gasoline Solenoid Direct Injection NAFTA

ES
q Engine Control Unit for Gasoline Solenoid Direct

Injection Systems q Standardized, scalable and modular electronic hardware q Chassis mounted q Supporting Euro 6, SULEV
q Engine Control Unit for Gasoline Solenoid

Direct Injection Systems
q Standardized, scalable and modular electronic

hardware
q Chassis mounted q Supporting Euro 5, SULEV

Technical Information
q Core q Flash size q Interfaces
TC1797, 150 MHz 3 MB 3*CAN, 1*Flexray, 1*Lin
q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing sealed q Connector pins q Pb-free
MPC5566, 128 MHz 3 MB up to 2 CAN 4/6/8 SDI (scalable) 44 + 1 H-Bridge IP6K9K 219 yes 19
q Injection drivers 4 SDI q Driver outputs 63 + 3 H-Bridges q Housing sealed IP6K9K q Connector pins 196
18
q Pb-free
yes
Engine Systems ES
ECU Gasoline & TCU Solenoid Direct Injection
EMS 3 Engine Management System Platform

ES
q Engine Control Unit for Gasoline Solenoid Direct

Injection Systems with integrated transmission control q Standardized, scalable and modular electronic hardware q Chassis mounted q Supporting Euro 5
q ECU for 3rd Gen. Engine Management Platform q Supports Gasoline, Diesel & Electrical Applications:
MPI, SDI (CoSI), PDI, Flexfuel, Variable Valve Lift, Highly Charged Engines, Integrated High Pressure Pump (HPP) Control, Boost-at-crank q Ready for Euro 6
20
q Core EMS q Core TCU q Flash size q Interfaces q Injection drivers q Driver outputs q Housing sealed q Connector pins
TC1767, 80 MHz TC1766 2 MB 1*CAN, 1*LIN 4 SDI 46 + 2 H-Bridges IPX9K 196
q Core q Flash size q RAM size q Interfaces q Injection drivers q Driver outputs q Housing q Connector pins q Pb free
Tricore & PowerPC, 80 264 MHz 1 4 MB 64 256 kB 1*CAN; up to 2*Flexray up to 12 Sent; LIN 2, 3, 4, 6, 8 Piezo, Solenoid 16 60 Aluminum or Magnesium up to 196 (300 in combination) yes 21
Engine Systems ES
ECU Gasoline Port Injection
ECU Gasoline Easy-U Port Injection

ES
q Engine Control Unit

for Gasoline Multipoint Injection Systems q Standardized, scalable and modular electronic hardware q Chassis mounted q Supporting Euro 5 and Euro 5+
q Ready-to-use Gasoline Engine Management

System for worldwide applications: Europe low budget vehicle segment, Russia, China, India, ASEAN, Middle East, South America q CNG variant available q Modular and scalable system for various engine and vehicle configurations incl. Euro 5 and EOBD q Supported by local application teams
q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing sealed q Connector pins q Pb-free
22
TC1738, 80 MHz 1.5 MB 1*CAN 3 or 4 MPI 27 IPX9K 115 yes
q Core q Flash size q Interfaces q Ignition driver q Injection drivers q Driver outputs q Housing sealed q Connector pins
MPC563, 60 MHz 1 MB or 1.5 MB 1*CAN, 1*K-line, 1*LIN 4 internal IGBT or external 4 MPI 24 IP6K9K 96 23
Engine Systems ES
ECU Diesel Piezo Common Rail
ECU Diesel Light Duty Engines

ES
q Engine Control Unit for Diesel Piezo Common Rail

Injection Systems q Standardized, scalable and modular electronic hardware q Chassis mounted q Supporting Euro 5 (potential for Euro 6)
q Engine Control Unit for Light Duty Vehicle

Engines (in emerging markets)
q Standardized, scalable and modular electronic

hardware
q Chassis mounted q Supporting Euro IV and Euro V

q Core q Flash size q Interfaces
TC1797, 180 MHz 4 MB 2 * CAN
q Core q Flash size q RAM q Interfaces q Injection drivers q Driver outputs q Connector pins
Freescale MPC5566, 80 MHz 24 MB 4 MB 2*CAN 4 20 + 2 H-Bridges 154 25
q Injection drivers 4 cylinder, single bank q Driver outputs 32 + 3 H-Bridges q Housing sealed IP5k9k q Connector pins 154
24
Engine Systems ES
ECU Platform for Commercial Vehicles
ECU Diesel Heavy Duty Engines

ES
q Diesel Engine Control Unit for ww applications q Modular and scalable HW approach to cover
various engine configurations for Euro IV through Euro VI q Supporting all current Solenoid Injection System q On engine mounted (with damping elements)
q Diesel engine management for Amplified

Common Rail and Pump-Line-Nozzle and other Solenoid Injection Systems q On-engine mounted with damping elements q Fullfill current emission requirements (EPA 2010+, Euro VI+, combined with SCR)
26
q Core q Flash size q RAM q Interfaces q Injection drivers q Driver outputs q Housing sealed q Connector pins q Pb-free
MPC5xxx / TC17xx 4 MB optional external RAM 4*CAN, 2*Flexray up to 12 20 + 2 H-Bridges IP6K9K 2 x 76 yes
q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing sealed q Connector pins
TriCore TC1796 1.5 MB 3*CAN 12 21 + 1 H-Bridge IP69K IP67 141 27
Engine Systems ES
ECU Aftertreatment Control
Gasoline High Pressure 1-Piston Pump

ES
q Cost optimal design for control of exhaust

aftertreatment systems (SCR, DPF) q Control unit suitable for 12 V and 24 V battery voltage q Cabin or chassis mounted control unit q CAN interface to NOx sensor and engine control unit
q Dry run capability q Mounted on top

of the camshaft
up to 200 bar q System pressure 0.5 up to 6 bar q Supply pressure q Temperature range 40 up to +150C digital valve q Control Drive cam driven q q World wide fuel compatibility
q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Connector pins
28
MPC543 Coral 1 MB 2*CAN, 1*SAE J1708 2 19 62
29
Engine Systems ES
Diesel High Pressure 1-Piston Pump
Diesel High Pressure 3-Piston Pump

ES
q Innovative
digital metering valve q Weight and package optimized high pressure pump
q Designed for the

high expectations and harsh environment of commercial vehicles
2,000 bar q System pressure 1.02 cm3 / rev q Design q Max. speed at full load 4,500 rpm 2,250 N (special 4,000 N) q Max. radial load Weight 6.5 kg q q ITP (Internal Transfer Pump) q Woldwide fuel compatiblity incl. special fuels
q System pressure q Displacement q Max. speed at full load q Max. radial load q Weight
up to 2,200 bar 0.4 cm3/rev 4,500 rpm 2,000 N < 2.4 kg
up to 240 k starts q Start/stop capability q Worldwide fuel compatibility incl. special fuels
30
31
Engine Systems ES
Gasoline Piezo Injector
Gasoline DI XL2 Solenoid Injector

ES
q Very fast & precise injection

(up to 4 injections /combustion cycle) q Extended linear flow range, high flow capability
q Improved linear flow range for turbocharged

engines
q High flexibility of spray characteristics to meet the

requirements of each target engine
q O-Ring or metal-to-metal sealing

50 up to 200 bar up to 50 up to 35 g /s 14.5 mg / injection 10% at 0.4 ms PW
q System pressure q Working flow range q Static flow q Dynamic flow
q System pressure q Working flow range q Static flow range
40 up to 150 bar up to 20 5 up to 17 g/s (at 100 bar at 70C)
32
2 mg /stroke q Min. dynamic flow ~ 15 m q SMD size q Opening / Closing time 150 s 94/ 98 4 q Spray angle 30 up to +140C q Temperature range q World wide fuel compatibility
4 mg /stroke q Min. dynamic flow 15 m q SMD size min. 300 s q Opening / Closing 35 up to 90 q Cone angle range 0 up to 30 q Bent angle range q World wide fuel compatibility
33
Engine Systems ES
Gasoline DI XL3 Solenoid Injector
Gasoline Deka VII Fuel Injector

ES
q Improved linear flow range for high-turbocharged

engines q High flexibility of spray characteristics to meet the requirements of side or central mounted engines q O-Ring or metal-to-metal sealing q Multiple injection capability q No needle bouncing
q Fast opening/closing, various packaging options q Flexible orifice configurations q Low pulse width with high linear performance
and low voltage sensitivity
40 up to 200 bar q System pressure up to 24 q Working flow range up to 20 g /s (at 100 bar at 70 C ) q Static flow range 3 mg/stroke at 40 bar q Min. dynamic flow q Max. functioning press. 260 bar min. 500 s dwell time q Multiple injection q Multi-stream technology max. 8 holes short, long, extended q Family layout q World wide fuel compatibility
q System pressure 1 up to 6 bar q Fuel compatibility Gasoline & Flex Fuel

(up to E100)
q Static flow rate q SMD size q Opening time q Closing time q Min. linear pulse q Possible
spray patterns
per applic. 0.95 up to 6.0 g /s ~ 60 up to 100 m with ASQUARED < 1.10 ms > 0.70 ms 1 up to 20 ms cone spray 10 up to 30 bent stream 5 up to 25 split stream 15 up to 30
34
35
Engine Systems ES
Diesel Piezo Common Rail (PCR) Injector
Diesel PCR New Generation Injector

ES
q Million times field proven technology q Reduced injector leakage for low CO2 emissions
and fuel consumption q Improved injection accuracy to meet Euro 6 / US Tier2 emission standards
q Excellent multiple injection stability due to needle

direct drive and needle closed loop control
q Reduced CO2 emissions q Enable future emission standards

Euro 6 / US Tier2, US OBD conformity approved
q Outstanding low noise (NVH)

up to 2,000 bar 0.8 (with quantity drift correction) mm 3
q System pressure q Min. quantity
7 q Max. no. of injections q Min. injection separation 200 s < 26 ml/min at 2,000 bar q Permanent leakage plus additional dynamic leakage
q System pressure q Min. quantity q Max. no. of injections q Min. injection separation q Permanent leakage
2,200 bar 0.5 mm 3 /shot 9 50 s 13 ml/2,200 bar, no additional dynamic leakage > 90 m Boot + Ramp 37
q Diameter nozzle holes q Closed loop control

36
> 90 m
(Injector Control Valve Adaptation ICVA)
q Diameter nozzle holes q Rate shaping
Engine Systems ES
Deka SCR Injector
Deka Injector for Diesel Dosing into Exhaust Gas

ES
q Single fluid airless system, compatible with purge

operation q Simple and reliable delivery of urea with excellent spray performance q Multiple spray configurations (Patented A2 and Enhanced Atomizer options available) q Increases overall system efficiency by using maximum synergies with existing technologies
q Robust approach for Diesel Particle Filter (DPF) q Uses existing injection technologies (production
and High Efficiency NOX Trap (HENT) regeneration control valve, nozzle design similar to DI injector)
q Avoidance of oil dilution by post injection leads to

longer oil change intervals, greater tolerance of bio diesel, and increased engine durability q Higher degree of flexibility for regeneration timing q Improved fuel economy
q Nominal static flow Qs 0.9 g/s (500 kPa, AUS32) q Nom. dynamic flow Qd 3.0 mg/pulse (500 kPa,
5 ms pulse, AUS32) (solid cone spray)
q Nominal spray angle 19 up to 31 degrees q SMD size q Fluid pressure range q Injector body temp. q Injector tip temp.
60 m (500 kPa, water) 380 up to 900 kPa 160C max. continuous 200C max.
q Delivery fuel mass range q Accuracy of flow q SMD size q Input pressure range q Max. control valve temp. q Max. spray nozzle temp. q System minimum pulse width
0.1 up to 8 g/s 7% 75 up to 150 m (Diesel Fuel) 350 up to 1,200 kPa 120C 500C 10 up to 20 ms 39
38
Engine Systems ES
Gasoline Turbocharger
ES
q Designed
for a fully integrated robotized assembly process
q Outstanding thermodynamics q Robust and reliable design

q Gasoline application up to 1050C exhaust gas

temperatures up to 250 kW per Turbo q Engine power Turbine wheel 30 up to 60 mm q max. 0.3 kg/s q Air flow max. 330,000 rpm q Speed q Integrated recirculation valve q Electric actuated wastegate control q Milled compressor wheel 40 41
Hybrid Electric Vehicle HEV
42
HEV
43
Hybrid Electric Vehicle
HEV
Power Electronics
Inverter with integrated converter t
Modular Li-Ion Energy Storage System
Single Inverter
q Modular design q Control module for electric machine in hybrid electric vehicle, electric vehicle and fuel cell vehicle
q Application in hybrid, electric and fuel cell vehicles q Safety and lifetime optimized cells q Synergy effect through modular system q Variable cooling system
q Water cooling
Inverter
q Power: up to 110 kW at 420 V q Converts energy in both directions drive electric

machine in motor and generator mode
Converter
q Power: 18 kW up to 120 kW q Li-Ion ultra high power cells q Integrated battery management q Integrated safety system q Integrated cooling system
q Power: up to 3 kW q Bi-directional potential free energy transport

between HV traction battery and 12 V power net
q Replaces conventional 12 V generator

44 45
HEV
s Single DC/DC Converter
High Voltage Axle Drive System
HV Side-Mounted Starter Generator
q High speed synchronous machine

(externally excited) q High power density q High efficiency q Cost-optimized
up to 12,000 rpm q High speed 450 V up to 690 V q High voltage Mechanical power 35 kW up to 70 kW continuous q 70 kW up to 140 kW peak
q High speed asynchronous machine q High power density q High efficiency q Low weight q Short axial length q Cost-optimized
q High speed q High voltage q Regenerative power
up to 18,000 rpm up to 150 V 5 kW continuous, 20 kW peak
q Fluid cooling q Aluminum housing q Mechanical integration of gearbox and e-machine
q Fluid cooling q Aluminum housing q Special stator winding design

47
46
HEV
Motor Control Unit for Hybrid /Electric Vehicles
14 V Modular Power Net System
q Central power train control unit q Flexible modular system q Scalable to customer requirements
q Energy storage for limited regenerative braking q Provides second voltage level for high power
applications (up to 4% CO2 reduction)
q Driver demand acquisition q Torque demand calculation q Recuperation during braking and deceleration q Energy management depending on battery
state of charge
q Support of start-stop q High number of load cycles q Modular and integrated designs available
q DC/DC converter 0.4 kW up to 2.6 kW

Voltage level 14 V up to 60 V Efficiency up to 94 % Bidirectional Potential-free and potential-connected designs available 3.6 Wh up to 50 Wh q Energy Storage With Double Layer Capacitors Includes active or passive balancing q Energy management & diagnosis (e.g. SOC, SOH) q CAN or LIN communication
q Battery charge management q Control of cooling system q Communication gateway q Low quiescent current: 100 A
48
HEV
49
Transmission TR
Transmission
TR
TR
50
51
Transmission TR
Control Unit for Double Clutch Transmission
q Integrated transmission control unit for dry

7-speed Double Clutch Transmission q Mechatronic module assembled in the gearbox q Higher reliability of the electronics due to the reduced number of internal connections q Weight reduction due to integration
q Integrated transmission
control unit for wet 7-speed Double Clutch Transmission (hydraulically controlled) q Mechatronic module assembled in the gearbox
q LTCC (Low temperature co-fired ceramics)

substrate for electronic components
q Ceramic substrate technology q 32-bit microprocessor q Operating temperature: 40C up to +140C q Direct connection of actuators to the control unit q Only one plug connection to the vehicle q Control of BLDC motor of oil pump q Maximum permissible acceleration
52
q Operating temperature: 40C up to +145C q Integrated in transmission surrounded

by transmission oil
q 11 close-loop controlled valves q Integrated sensors:

4 2 2 1 position speed pressure temperature 53
TR
Transmission TR
q Integrated transmission control unit for
wet 7-speed Double Clutch Transmission (hydraulically controlled) q 4 WD applications, longitudinal installation of the engine
q Integrated transmission control unit

for wet 6-speed Double Clutch Transmission
q Mechatronic module assembled in the gearbox

q Ceramic substrate technology q 32-bit microcontroller q Operating temperature: 40C up to +145C q Vibrations up to 20g q Integrated sensors:
54 temperature pressure speed gear position
q Ceramic substrate technology q 32-bit microcontroller q Operating temperature: 40C up to +140C q Drivers: 9 solenoids (4 prop. + 5 on/off) q Sensors:
4 2 2 1 1 linear position speed pressure temperature transmission range sensor 55
TR
Transmission TR
q Mechatronic control unit for dry 7-speed

Double Clutch Transmission q Includes 2 BLDC motors
q External transmission control unit for

wet 7-speed Double Clutch Transmission
q Hydraulically controlled
q PCB technology q 32-bit microcontroller q Operating temperature: 40C up to +140C q Power module operates 2 BLDC motors
for gear actuation
q Controls 2 external clutch actuators
q PCB technology q 32-bit microcontroller q Operating temperature: 40C up to + 85C q Mounted in vehicle cabin q 9 solenoids (7+2) q PCB screwed on aluminum plate and cover
with 2 connectors of 42 pins each
56
TR
57
Transmission TR
Control Unit for Stepped Automatic Transmission
q Integrated control unit for 7-speed stepped

Automatic Transmission q Mechatronic module assembled on valve body of gearbox
q Control unit for

6-speed Automatic Transmission
q Mechatronic module assembled in the gear box q Integration of all transmission sensors q Weight reduction due to integration q Higher reliability of the electronics due to reduced
number of internal connections
q LTCC substrate for electronic components q 32-bit microcontroller q Operating temperature: 40C up to +140C q Flex-foil for electrical interconnection to sensors
and 5 pin vehicle connector

q Integrated speed and temperature sensors q 8 power outputs for solenoids with integrated
connectors
q E-Module based on flex technology q Powerful 32-bit microcontroller q Operating temperature: 40C up to +143C q Position, speed and temperature sensors
integrated 59
q 3 integrated speed sensors

1 position sensor 58
TR
Transmission TR
q External control unit for 5-speed Automatic

Transmission q Transmission for rear-wheel drive vehicles q Mounted in engine compartment
q Stand-alone transmission control unit for 5-speed

and 6-speed Automatic Transmission
q PCB technology q 16-bit microprocessor q Operating temperature: 40C up to +140C q Power outputs for 6 electromechanical
hydraulic valves: 2 control valves for the hydraulics of the transmission 3 control valves for the gear changing 1 valve for bypass converter
q PCB technology q 32-bit microcontroller q Operating temperature: up to +105C q Chassis mounted q Sealed housing
q Protection class: IP 50 (DIN 40050 T9)

60 61
TR
Transmission TR
ECU for Continuously Variable Transmission
q Electro-hydraulic control unit for 6-speed

Automatic Transmission q Integrated transmission control unit including manifold and solenoids q Monitors transmission performance and compensates for normal wear in components such as clutch plates, so transmission performance remains consistent for the life of the transmission
q Integrated transmission
control unit for Continuously Variable Transmission for front-wheel drive applications

q 32-bit microprocessor with external flash memory q Operating temperature: 40C up to +140C q 14-pin vehicle interface connector system
q Ceramic substrate technology q 32-bit microcontroller q Operating temperature: 40C up to +145C q Vibrations up to 20g q Integrated sensors:
temperature pressure speed transmission selector lever 63
62
TR
Transmission TR
EAST Transmission Control Unit
Control Unit for Transfer Case
q Control unit for stepped AT, CVT, DCT, hydraulic

and electric AMT q Stand-alone concept q Reduced time-to-market thanks to existing platform q Cost efficient solution
q Control unit for high/low shift and active torque

distribution of transfer cases used in four-wheel drive vehicles q For improved traction on-road and off-road
q PCB technology q 32-bit microcontroller with internal flash memory q Operating temperature: up to +105C q Environment: engine or passenger compartment q Flame Retardant 4 (FR4) printed circuit board
substrate
q PCB technology q Powerful 16-bit microprocessor q Operating temperature: up to + 85C q Flame Retardant 4 (FR4) substrate for electronic
components
q State of the art input/output stages

64
q Power output for one actuator motor q Protection class IP40 q Stand-alone housing with integrated cooling plate
65
TR
Transmission TR
Control Unit for Limited Slip Coupling
Transmission Control Unit for CV
q Control unit for limited slip coupling of 4WD

control applications q Controls a valve and feeder pump to change torque distribution between front and rear axle q Unit directly attached to 4WD coupling
q External transmission control module for

ultrashift and autoshift applications in commercial vehicles (CV)
q PCB technology q Powerful 16-bit microprocessor q Flame Retardant 4 (FR4) substrate for electronic
components
q Stand-alone module, transmission mounted q 32-bit microcontroller, with up to 2.5 MB memory q Operating temperature: up to +105C q 76 way module I/O connector q Communication via Hardwire and CAN
q Power outputs for one valve and oil pump q Operating temperature: up to +105C q Integrated connectors for solenoid and pressure
sensor
q Integrated LC-module
66 67
TR
Transmission TR
Automatic Transmission Control Unit for CV
Transmission and Retarder Control Unit
q Control unit for 6-speed Stepped Automatic

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

and Retarder for commercial vehicle applications
q Control unit directly mounted on the transmission

or retarder
q Improved performance characteristics q Higher service life q Reduced driving noise development q Reduced harness length and complexity
q PCB technology q Powerful 32-bit microprocessor q Operating temperature: up to +105C q HDI organic substrate q 10 power outputs for solenoids q 3 VRS speed inputs q CAN, J1708, J1850, K-Line communication q 18 switch inputs
q Ceramic substrate and direct copper bonded

technology
68
q 32-bit microcontroller q Operating temperature: 40C up to +140C q IP6k9 housing with overmolded leadframe q 24 V/12 V capable q 2 x CAN-Bus and current control outputs (10)
TR
69
Sensors & Actuators S & A
Sensors & Actuators
S&A
S &A
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71
S & A Actuators
Air Control Valve (ACV-S) Economy Line
Air Control Valve (ACV-S) Performance Line
q Low cost, full functional range Electronic Throttle

Body actuator for diesel combustion engines q Non-contacting position sensor q Low weight, small package q Good crash behavior q Capable for LP EGR environment
q High temperature
Electronic Throttle Body actuator for diesel combustion engines q Non-contacting position sensor q High torque, fast response q Very good EMC performance q Capable for LP EGR environment
q Temperature range intake air q Temperature range environm. q Excess torque q Response time (typ.) q Pressure range q TP diameter range
40 up to +140C 40 up to +140C > 1 Nm (13.5 V, RT) 130 ms (13.5 V, RT) up to 3.5 bar peak 40 up to 57 mm
40 up to + 230C 40 up to +160C > 1.6 Nm (13.5 V, RT) 100 ms (13.5 V, RT) up to 3.5 bar peak 40 up to 57 mm 73
72
S &A
S & A Actuators
Air Control Valve (ACV-S) MD/HD CV Line
Air Control Valve (Smart ACV)
q Modular Electronic
Throttle Body actuator for medium and heavy duty diesel combustion engines, capable for 12 V and 24 V systems q Non-contacting position sensor q High torque q Capable for big TP diameters q Capable for LP EGR environment
q Intelligent Electronic
Throttle Body actuator for diesel combustion engines q Integrated control unit with processor and H-bridge for DC motor on-board q Easy to integrate into existing systems q Non-contacting position sensor q Capable for LP EGR environment
40 up to +140C > 1.6 Nm (13.5 V, RT) 100 ms (13.5 V, RT) up to 3.5 bar peak 57 up to 100 mm
q Temperature range intake air 40 up to +140C q Temperature range environm. q Excess torque q Response time (typ.) q Pressure range q TP diameter range
74
40 up to +120C 40 up to +140C > 1 Nm (13.5 V, RT) 150 ms (13.5 V, RT) up to 3.5 bar peak 57 up to 80 mm 75
S &A
S & A Actuators
Brushless DC Drives High Efficiency
Canister Purge Solenoid (CPS)
q High efficency Brushless DC drives for use in

double clutch, AWD-disconnect, Oil pumps, ... q Small package q Low weight
q Different performance classes 50 W up to 200 W 40 up to +140C q Temperature range
50 up to 85 SLPM q Flow at 500 mm Hg 14 V q Nominal operating voltage Coil resistance 17 Ohms q PWM q Control circuit 5 Hz up to 32 Hz q Operating frequency 40 up to +140C q Operating temperature q Total leakage at 500 mmHg < 20 SCCM q Sonic regulated above 100 mmHg
76
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77
q Canister regeneration with a PWM solenoid q Linear flow curve, sonic nozzle flow control q Fast response, light weight, compact size q Various mounting options available q Direct manifold mount w. NVH suppression feature
S & A Actuators
Canister Purge Solenoid (CPS)
Digital Linear Actuator for Idle Air Control Valve
High Flow
Gen I
feature
q Provides high flow for Turbo, HEV, Continuous

Variable Valve Lift, Start & Stop applications
q Check valve options available

Technical Information 50 up to 110 SLPM q Flow at 500 mmHg 14 V q Nominal operating voltage 24 Ohms q Coil resistance PWM q Control circuit 5 Hz up to 32 Hz q Operating frequency 40 up to +140C q Operating temperature q Total leakage at 500 mmHg < 20 SCCM q Sonic regulated above 100 mmHg
78
q Operating Voltage q Inductance per winding q Resistance per winding q Resolution q Total travel q Operating temperature q Weight q Vibration
12 V (7.5 V/14 V) 33.5 mH 53 Ohms 0.04167 mm / step 8.5 mm (204 steps) 40 up to +125C 110 g 35 up to 40 G 79
S &A
q Canister regeneration with a PWM solenoid q Linear flow curve, sonic nozzle flow control q Fast response, light weight, compact size q Various mounting options available q Direct manifold mount with NVH suppression
q The idle air control system provides a consistent,

stable idle speed throughout the service life of the vehicle (maintenance free) q The air flow characteristic is tuned to the application needs by changing the pintle profile q The actuator (DLA) can be integrated into air induction system
S & A Actuators
Digital Linear Actuator for Idle Air Control Valve
Electric EGR (EEGR)
Gen V
q The idle air control system provides a consistent,

stable idle speed throughout the service life of the vehicle (maintenance free) q The air flow characteristic is tuned to the application needs by changing the pintle profile q Plastic sleeve design for partial or complete integration into a throttle body
q Electric Actuation has faster response and more

control than conventional vacuum systems
q Eliminates vacuum regulator and q Can be tailored to customer flow requirements

80
q Operating Voltage q Inductance per winding q Resistance per winding q Resolution q Total travel q Operating temperature q Weight q Vibration
12 V (7.5 V/14 V) 33.5 mH 53 Ohms 0.04167 mm / step 8.5 mm (204 steps) 40 up to +125C 50 g 30 up to 35 G
q Nominal operating voltage q Current consumption

at max. flow
13.5 V 1.0 A at 20C 1.5 A 8.0 Ohms at 20C 90 Hz up to 175 Hz 5V
q Max. current consumption q Nominal coil resistance q Nominal operating frequency q Position sensor supply voltage q Response time (total stroke)
< 50 ms (open to close or close to open) 81
S &A
connecting hoses
S & A Actuators
Electronic Throttle Control (ETC)
Electronic Throttle Control (ETC)
ETC Economy Line
ETC Performance Line
q Low cost,
full drive-by-wire Electronic Throttle Body actuator for gasoline combustion engines q Modular available with plastic or aluminum die-cast housing q Non-contacting position sensor q Low weight, small package
q High performance Throttle Body actuator

for gasoline combustion engines
q Temperature range intake air q Temperature range environm. q Excess torque q Response time (typ.) q Pressure range q Leakage (at stop) q TP diameter range
82
40 up to +125C 40 up to +140C > 1 Nm (13.5 V, RT) 130 ms (13.5 V, RT) up to 3.5 bar peak < 3 kg/h (52 mm) 40 up to 57 mm
q Temperature range intake air q Temperature range environm. q Excess torque q Response time (typ.) q Pressure range q Leakage (at stop) q TP diameter range
40 up to +140C 40 up to +160C > 1.6 Nm (13.5 V, RT) 100 ms (13.5 V, RT) up to 2.5 bar peak < 1.7 kg / h (52 mm) 40 up to 80 mm 83
S &A
q Non-contacting position sensor q High torque, fast response q Very good EMC performance q High temperature capabilities
S & A Actuators
Exhaust By-pass Valve (EBV)
Exhaust Control Valve High Pressure
q Design options available to fit customer

requirements q Easy integration into EGR cooler q Flexible housing design q Leakage to atmosphere < 0.5 kg / h at 3 bar q Electrically actuated valves are also available
q Provides both accurate low flow precision

(improves engine performance) and high volume flow (improves emission reduction) by maintaining low gas pressure drop q Non-contacting sensor, flexible output, not sensitive against magnetic fields, well known control strategy q Compact, light weighted size and water cooled additional shaft bearing to withstand high pressure pulsation
q Operating ambient
temperature range 40 up to +140C 600C (short term 650C)
q Exhaust gas temp. q Actuator opening
design capability range < 100 ms
q Mechanical closing
design capability range < 100 ms
84
q Torque at flap: 230 Ncm q Response time (85%): < 80 ms q Nominal supply voltage: 13.5 V or 24 V q Position sensor supply voltage: 5 V q Maximum flow: up to 190 kg / h at 50 hPa q Exhaust temperature: up to 700C
S &A
85
S & A Actuators
Exhaust Control Valve Low Pressure
Exhaust Throttle Valve (ETV)
q Provides both accurate low flow precision

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

pressure EGR flow
q Resistant to external aggression: stone projection, q Resistant to corrosion using specific materials,
i.e. flap housing off precision casting or welded stainless steel technology
86
Technical Information q Response time (t90): < 90 ms q Nominal supply voltage: 13.5 V q Position sensor supply voltage: 5 V q Maximum flow: 245 kg/h at dP20 hPa q Internal leakage: 3 kg/h at dP 600 hPa q Max. differential pressure over flap: 300 kPa q Exhaust gas temperature: 100 up to 200C
q GPA technology used for actuation

Nominal supply voltage 13.5 V Position sensor supply voltage 5V
q Maximum flow
up to 420 kg/h at dp 50 hPa
< 100 ms q Response time (t90) q Exhaust gas temperature 800C 87
S &A
gravel, water splashes
S & A Actuators
General Purpose Actuator (GPA)
Linear Purge Valve (LPV)
q Continuous adjustment
of external application using rotating output shaft q Ideal for use in turbocharger applications q Option: Default Position q Permanent feedback signal (non-contacting)
q Canister regeneration with a linear proportional

solenoid
q Very low operating noise due to constant current q Fast response for incremental flow control at all
operating conditions
q Excellent low end flow control to prevent

unwanted surges of fuel vapor
q Max. external load

without return function 86 Ncm less than 100 ms at 140C q Response time q Operation temperature 40 up to +140C
q Typical flow q Operating voltage q Coil resistance q Maximum current q Control circuit q Weight
70 SLPM at 57 kPa 14 V 14.0 Ohms 500 mA Constant current at 150 up to 200 Hz 200 g 89
88
S &A
input
S & A Actuators
Pump (EWP ) Electrical Water Pump
Pump (SCP) Smart Coolant Pump
q Variable small coolant pumps for engine and

power electronics cooling as well as cooling of the turbocharged air q Use of energy meeting the demands q Operation independent from main cooling circuit q Operation independent from combustion engine operation
q Precise engine temperature control through

variation of coolant volume flow
q Operation independent from engine for fuel
q Electronically commutated BLDC motor;

wet running rotor
q Modular design concept with or without integrated

speed control electronics
90
q Volume flow q Differential pressure q Hydraulic power q Coolant temperature range
700 up to 1800 l / h 500 up to 900 hPa 10 up to 45 W 40 up to +128C
q Electronically commutated BLDC motor q Integrated electronics in thick film technology q Wet running permanent magnet rotor 9000 l / h q Volume flow 800 hPa q Differential pressure 200 W q Hydraulic power 32 A q Supply current at Pmax q Coolant temperature range 40 up to +128C
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S &A
economy, comfort, and advanced propulsion applications
S & A Actuators
Pump (TOP) Transmission Oil Pump
Variable Lift Control Actuator
Brushless DC-Motor
q Automatic or Double Clutch Transmissions with

Full Hybrid or Start-Stop Systems q Continental as system supplier for all three components q E-Motor and electronics from one source q Already serial production history with integration of motor, pump, and electronics in one unit
(small package)
q Electronically commutated BLDC motor

with or without sensor
q Electric power: ~ 150 W up to 700 W q Electronics ambient

temperature capabilities: up to 140C
q EC motor q Diameter q Length q Weight
M42 42.6 mm 70.0 mm w/o connector 567 g
q Available pump types

depending on requirements Vane-type G-Rotor
q Max. EC motor power 480 W 70 Ncm with current q Stall torque

limited by the ECU
q Temperature range
40 up to +140C 93
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S &A
q Continuous positioning of eccentric shaft q Adjusts valve lift q High dynamics (low inertia) q Closed loop control via integrated position sensor q EC motor mounted in cylinder head
S & A Sensors
Door Handle Sensor
Fluid Level Oil Level Switch
q Easy to integrate into the door handle q Low power consumption

(< 100 A for double zone sensor)
q Low oil level detection q Different connectors possible q Simple on /off output
environment conditions (rain, fog, snow...)
q Capacitive sensor for Keyless Entry System q Detection distance 0 up to 40 mm < 5 ms up to 30 ms q Response time q Optional:
94 Capacitive sensor for door locking Mechanical switch for door locking Movement sensor LED for ground / pocket illumination LF antenna integration NFC reader (access with mobile phone)
q Measuring principle: magnetic reed switch q Different switch heights possible q Normally on (switch closed) q Tolerance: 1 mm
S &A
95
q Reduced false detection thanks to adaptation of
S & A Sensors
Fluid Level Sensor Capacitive QLT
Fluid Level Sensor Ultrasonic
QLT = Quality Level Temperature
q Overfill and low level indication q Absolute measurement of oil level in static and
dynamic conditions. Replacement of oil dipstick
q Replacement of oil dipstick q Detection of low level and overfill q Absolute measurement of oil level in static q Stand-alone sensor with integrated electronics
(active) and ASIC
(active) q Oil quality information (permittivity) q Extension of the oil change intervals
q Low power consumption q Temperature measurement optional

Technical Information q Measuring principle q Measuring range q Accuracy q First measurement available q Power supply q Measuring interval q Operating temperature Level Temperature
ultrasonic echo 18 mm up to 120 mm 2 mm 0.4 sec after key-on 12 V /10 mA typical ~ 1 sec. 10 up to + 150C 40 up to + 150C
q Measuring principle q Measuring range q Accuracy q First measurement available q Measuring interval q Permittivity measuring
96
capacitive 40 up to 120 mm 2 mm in 1.4 sec after key-on ~ 1 sec.
range (quality) 1 up to 6 Typical value for engine oils 2 up to 3
q Temp. measuring range
40 up to + 160C
S &A
97
q Stand-alone sensor with integrated electronics
and dynamic conditions
S & A Sensors
Fluid Level Sensor Passive Electrothermic
Fluid Quality Flex Fuel Sensor
q Overfill and low level indication q Absolute measurement of oil level in static and
dynamic conditions q Replacement of oil dipstick q Different mounting positions q Temperature measurement optional
q In line sensor mounted between fuel tank

and engine
operation thermoresistive heated wire 110 mm betw. min. & max. approx. 3 mm available 0.6 s after key-on > 5 sec max. ~200 1 mA (pulse mode)
q Measuring principle q Measuring range q Accuracy q First measurement q Measuring interval q Current consumption
q Active temperature and conductivity compensation q Simple compact design, proven safe and reliable q Various connector interfaces available
q Measures Ethanol content

of Ethanol / Gasoline mix 0 up to 100% 5% on Ethanol q Accuracy q Frequency output based on percent Ethanol 40 up to +125C q Operating temperature 9 up to 18 V q Supply voltage 400 l / h (80 g/s) q Maximum flow
98
q Operating temperature 40 up to + 160C q Temp. measurement optional with NTC ( 2C)
S &A
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q Ethanol content determined prior to combustion q Meets OBD II functional requirements q Allows usage of saddle tanks on flex fuel vehicles q Reduces the likelihood of engine stall for safer car
S & A Sensors
Fluid Quality Flex Fuel Sensor
Fluid Quality Fuel Quality Sensor
High Integrated
q Next generation in line Flex Fuel Sensor mounted

anywhere between the fuel tank and engine q Design is smaller and more compact for ease of packaging q Assembly capable of various mounting methods q Accuracy equivalent or better than current design q Qualified for higher vibration profiles (engine mount) q Allows for emission and cold start improvements q Self diagnostics capability
q Real time optimization and protection of engine

and exhaust gas aftertreatment system
Technical Information (A-samples)
q Measures Ethanol content

of Ethanol / Gasoline mix 0 up to 100%
100
q Frequency output based on percent Ethanol 40 up to +150C q Operating temperature 9 up to 18 V q Supply voltage 400 l / h (80 g/s) q Maximum flow
q Optical principle (infrared dispersive spectroscopy) q Measurement location in fuel line (in tank possible) 10 bar max q Pressure range q Temperature range 40 up to + 85C CAN q Output signal 30 s (for complete fuel parameter set) q Response time q Diesel parameters: cetane number, bio
concentration, density, heating value, aromatics, sulfur content classification, misfuel warning
q Gasoline parameters: RON, density, oxygen

(ethanol) content, RVP, distillation curve 101
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q Reduction of pollutant emission and fuel economy q Improvement of drivability (e.g. knocking, cold start) q Fuel quality data logger
S & A Sensors
Hydrocarbon Sensor
In-Cylinder Pressure Sensor
q Detects concentration of a 2 gas compound

mix up to 100% q Applications possible: CNG, canister purge, crankcase ventilation, etc. q Optimized regeneration of charcoal canister q Reduce system costs e.g. by avoiding usage of high pressure fuel tanks q Optimized Engine-Management: can help to optimize injection time and injected fuel volume depending on the purged HC gas from purge canister and/or crankshaft housing
q Stand-alone sensor allowing closed-loop

combustion control for gasoline and diesel engines q Easy to integrate q Reduces emissions q Increases engine power q Reduces fuel consumption q Simple and robust solution
q Ultrasonic sensing technology q Operation temperature 40 up to + 80C 0% up to 100% q Measuring range

HC concentration 102
q Accuracy: 3.5% q Various connector designs q Active sensor q Small size sensor: M8 thread
q Response time q Accuracy
~ 50 ms 2 up to 3% (Butane) 103
S &A
S & A Sensors
Knock Sensor Wide Band
Mass Airflow Sensor
1 1 In-Tube MAF Sensor 2 Plug-In MAF Sensor
q Used to optimize ignition timing for maximum

efficiency q High sensitivity q Compact design, nested bolt possible q Increases engine power q Decreases fuel consumption
q High flow measurement accuracy and exceptional

signal stability characteristic
q Excellent performance with intake airflow pulsation q Low power consumption and fast start-up time q Flow range adaptable for secondary airflow (SAF)
and fuel cell applications
q Acceleration sensor based on piezo ceramic

technology with a range of: 0 up to 400 g
q Frequency range: 3 up to 25 kHz q Possible integration of discharge resistor q Integrated connector or cable version q Various connector designs
104
q Sensing technology Hot-film bi-directional MEMS 5 up to 800 kg/h (62 mm tube) q Flow range q New-part tolerance 1.5% 5 V 0.5 V q Supply voltage 10 mA maximum q Supply current Frequency or SENT digital q Output signal q Integrated intake air temperature sensor optional
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q Integral protection against water and contamination q Customer specific programmable output
S & A Sensors
Natural Vacuum Leak Detection (NVLD II)
Position Sensor Linear Contactless
Hall Effect Technology
q With, or without Integrated

Electronic (NVLD II smart) q Diagnostic performed after key off q Stand-alone or canister mounted versions q Temperature sensing q Pressure switch sensing q Timer function
q Sensor is smaller than stroke q Through wall measurement, high airgap q Applications: Neutral gear (X-Y, Neutral + Rear,
q Overall accuracy q Target
q Vacuum sensing switch with 2.5 0.3 mbar

calibration
min. 2% (incl. ageing, temperature, airgap) Magnet (compatible with through Al wall sensing)
q Damping feature to avoid noise q Weight approx. 100 g q Bit serial communication with ECU q Average current consumption < 50 A q High In Use Monitor Performance Ratio
106 (IUMPR > 80%)
linear up to 60 mm q Measurement up to 11 mm q Airgap q Operating temp. range 40 up to +150C 5 V 0.5 V q Operating voltage Analog, PWM, SPI or SENT q Output signal q X-Y measurement possible
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107
or detent pin integrated), clutch cylinder, transmission fork, Park Lock, PRNDL, pneumatic valve covers...
S & A Sensors
Position Sensor Linear Contactless
Position Sensor Rotary Contactless
Inductive Technology
Inductive Technology
Transmission position sensors: PRNDL, Clutch Master Cylinder, Gear, DCT fork Engine position sensors: thermal management valve, EGR, Turbo
engine management stand alone sensors (VVL, swirl, portflap...) and actuator covers (VVL, ACV, ETC, EGR), thermal management
q Measuring range q Overall accuracy q Airgap q Linearity q Operating temp. range q Max. drift over temperature q Output signal
10 mm to 60 mm 2% (incl. ageing, temperature, airgap) 0.5 up to 3 mm < 1% full scale 40 up to +160C < 1% Analog, PWM or SENT
q Measuring range q Overall accuracy q Airgap q Linearity q Operating temp. range q Max. drift over temperature q Output signal
up to 360 2% (incl. ageing, temperature, airgap) 0.5 up to 3 mm < 1% full scale 40 up to +160C < 1% Analog, PWM or SENT 109
108
S &A
q Easily configurable for redundancy q Target is non-magnetic (Al, Fe, ...), low cost q No hysteresis, no pollution through iron particles q Immune versus low frequency magnetic field q Applications:
q Easily configurable for redundancy q Target is non-magnetic (Al, Fe, ...), low cost q No hysteresis, no pollution through iron particles q Immune versus low frequency magnetic field q Applications: transmission range, transfer case
S & A Sensors
Position Sensor Rotary Contactless
Pressure Sensor Fuel High Pressure
Magneto-Resistive Technology
GDI and DDI
q Sensor only sensitive to magnetic field orientation

(not strength) q Sensor is immune to external magnetic field due to the target wheel / sensor configuration q Contactless sensing no mechanical wear (improved reliability and durability) q Applications: stand alone and actuator coupled VVL, ACV, ETC, EGR
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q Large measurement range q High accuracy and temperature stability q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
110
q High accuracy of MR technology ( 1) q Redundant / self diagnostics q Analog or SPI digital output 0.022 resolution q High accuracy q Measuring range 0 up to 180 q Temperature range 40 up to +160C < 0.1 q Hysteresis
q Pressure range q Accuracy q Temperature range q Supply voltage q Supply current at 5 V q Load resistance q Response time q Output signal
0 up to 2200 bar 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW < 1 ms Analog or SENT 111
S &A
S & A Sensors
Pressure Sensor Low Pressure Absolute
Brake Booster Absolute (BBA)
MAP, TMAP, BAP
q Direct measurement of vacuum q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic response q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
q Pressure Range q Accuracy q Temperature range q Supply voltage q Supply current at 5 V q Load resistance q Output signal
10 up to 120 kPa 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW Analog or SENT
q Pressure Range q Pressure Range q Accuracy q Temperature range q Supply voltage q Supply current at 5 V q Load resistance q Output signal
7 up to 500 kPa (for BAP) 20 up to 300 kPa (for MAP and Turbo MAP) 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW Analog or SENT 113
112
S &A
S & A Sensors
Pressure Sensor Low Pressure Differential
Secondary Air Absolute (SAA)
Brake Booster Gauge
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic response q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
q Direct measurement of vacuum q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic response q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
50 up to 150 kPa (for SAA) 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW Analog or SENT
114
105 up to 40 kPa (gauge) 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW Analog or SENT 115
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S & A Sensors
Filter Control Gauge
Manifold Gauge
q Adjustable characteristic via electronic calibration 0 up to 10 kPa q Pressure range q Operating temperature 40 up to +125C 5 V 0.25 V q Supply voltage linear, ratiometric q Transfer function q Accuracy over full-scale 3% full span
(10 up to 85C) 116
q Pressure range q Accuracy q Temperature range q Supply voltage q Supply current at 5 V q Load resistance q Output signal
105 up to 40 kPa (gauge) 1% full scale (10C up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW Analog or SENT 117
q Output signal
Analog or SENT
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S & A Sensors
Particulate Filter Differential
Particulate Filter Gauge
q Differential measurement of the exhaust gas

pressure across the diesel particle filter q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q Large measurement range q High accuracy and temperature stability
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Fulfills toughest EMC requirements q Flexible housing, connector, and mounting designs
q Pressure range
0 up to 100 kPa P1 (downstream port) 0 up to 50 kPa P2 (upstream port) 0 up to 150 kPa Programmable (0.200 up to 4.800 V) 0.8% FSS (0 up to 70C) 40 up to +125C <1 ms
q Operating voltage q Accuracy q Temperature range q Response Time
118
q Pressure range q Accuracy q Temperature range q Supply voltage q Supply current at 5 V q Load resistance q Response time q Output signal
0 up to 125 kPa 1% full scale (10 up to 85C) 40 up to +140C 5 V 0.5 V 10 mA maximum > 4.7 kW < 2 ms Analog or SENT 119
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S & A Sensors
Smart NOx Sensor
Smart Particulate Matter (PM) Sensor
Calibrated High Accuracy NOx Sensor q Sensor detects NOx and Oxygen concentration up- /downstream of exhaust after treatment components compliant with OBD legislation q Self diagnosis capability regarding signal degradation and shortcut / open wire q All electronics including heater control and drivers integrated in the sensor q Standardized electronic interface with CAN-Bus
Calibrated Stand-Alone PM Sensor q Detects soot particle concentration downstream of Diesel particle filter compliant w. OBD legislation q Supports Real time measurement of particle concentration q Shortcut and open wire self diagnosis capability q All electronics including heater control and drivers integrated in the sensor q Standardized electronic interface with CAN-Bus
q Measuring principle ZrO2-based multilayer sensor with integrated heater and 3 oxygen pumps q Triple output signal NOx, binary , linear
or O2 concentration 12 V or 24 V q Supply voltage CAN 2.0 or SAE-J-1939 q Data link q Operating gas temp. 100 up to 800C
q Measuring principle Al 2 O 3 -based sensor with q Output signals
resistive measuring electrode
PM in mg/m3, regeneration frequency
120
12 V or 24 V q Supply voltage 0 up to 25 mg/m3 q Measuring range q Operating gas temp. 100 up to 400C
S &A
121
S & A Sensors
Temperature Sensor Coolant / Fuel / Oil
Temperature Sensor High Temperature
q Clip or screw-in design q Wide range of applications q High accuracy q Short response time q Long-term stability q Certified quality q High worldwide volume production
resolution of temperature signal (12 bit)
q Smaller package of sensing probe is possible

q Oil, water, fuel, temperature measurement

Engine coolant 40 up to +150C Engine oil 40 up to +150C Fuel 40 up to +140C
q Output signal: LIN, PWM, CAN, SENT,

5 V analog ratio
q Accuracy q Response time
1C (at 0C) up to 3s
q Response time: 6 s at 10 m/s (4 s at 20 m/s gas) 40 up to +1200C q Sensing temperature 40 up to +125C q Working temp. electronics
(+140C optional)
122
q Accuracy low temp. (< 500C) 5C q Accuracy high temp. (> 500C) 10C 5 up to 24 V q Supply voltage
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123
q Active sensor price in the range of a passive q High accuracy (Thermocouple principle) q Price benefit for customer at ECU-system q Lower signal ageing over lifetime q Fast response, high robustness and higher
S & A Sensors
Temperature Sensor Intake Air
Temperature Sensor EGR
q Clip or screw design q Wide range of applications q High resolution q Short response time q Long-term stability q Certified quality q Open or closed design
q Measures intake air temperature

with high EGR rates
q Optimized design for high temperatures q Very robust q Certified quality q No chemical and soot impact on Pt q Cable version in development
q Intake air temperature measurement q Intake air temperature 40 up to +150C q Diesel and gasoline application up to 4 s q Response time
q Temperature range 40 up to + 400C q Short response time up to 7 s
124
S &A
125
(up to 400C) in case of connector version
S & A Sensors
Temperature Sensor Outside Air
q Splash-proof plastic housing q Easy snap-in installation q Price benefit q High accuracy q Long-term stability q Certified quality q High worldwide volume production
q Outside air temperature measurement q Outside air temperature: 40 up to +120C q Different NTC curves possible q Average 1C over temperature range
126
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127
Fuel Supply FS
Fuel Supply
FS
FS
128
129
Fuel Supply FS
Modular Fuel Supply Unit
Modular Fuel Level Sensor with MAPPS
MAPPS ( MA gnetic Passive Position Sensor)
New Generation
q Various
customer specific designs possible based on modular concept q Flange geometry can be adapted to customer requirements q Integrated tank management q Variants: constant flow or flow controlled
q Redundant contacts q Best EMC because of passive system q Longer life time ( > 10 million cycles) because of
wear-resistant measurement system
q Hermetically sealed contacts assure perfect protection against contamination of all types of fuel
q Different fuel pumps ( 38 mm /43 mm) with EC (electronically commutated) or DC (direct current) motor q Integrated lifetime fuel filter q Integrated pressure regulator q MAPPS ( MAgnetic Passive Position Sensor)
130 fuel level sensor
q Measuring range q Operating current q Resolution q Max. total error of resistor q Interface q Operating temperature q Dynamic strength
angle up to 86.7 1 up to 20 mA 1.7 ~ 2% = 1% 2-wire resistance signal, 50 up to 1000 linear voltage at ADC 40C up to + 125C 200 m/s (0 Hz...1 kHz) 131
FS
Fuel Supply FS
Code Description for Names of Fuel Pumps

stands for the pump motor resp. the pump commutation = Copper Commutator = Carbon Commutator = Electronic Commutator (brushless)
EC Fuel Pumps (43 mm)

1
M ## P [ P..] f [ f..] /C
stands for special features
p lastic pump
(one f for each special feature)
/ EC
/ Cu
/C
/C
s hort fuel
pump
stage
1 D43Gp/EC 2 G43D/EC
D ouble turbine
(one P for each pump stage, main stage on first position)
stands for the pump principle
q In-tank fuel pumps with electronically commutated

(EC) motor
G erotor
T urbine
q Twin channel turbine pump stage (Gasoline) q Gerotor pump stage (Diesel) q Emission reduction q Essential pump control electronics offer demand
controlled operation
stands for the diameter
Tech. Information
28 mm 38 mm 43 mm 50 mm B io Diesel F lex Fuel Pressure, KPa Flow, l / h typ. Speed, 1/min. Power, W typ.
G43D/EC
500 245 7000 115 Premium, Unleaded, Tropical, Flex Fuel 43 mm
D43Gp/EC
500 245 5800 90 Diesel/RME
stands for the media
##
G asoline
T ropical
D iesel
q Media
L PG
132
q Diameter
43 mm
FS
133
q Working point example:
Fuel Supply FS
Fuel Supply Electronics
Modular Function Carrier (MFC)
q Enhanced fuel pump lifetime in comparison

to systems without demand control q Reduced consumption of electric energy q Reduced noise and emission level
q Suitable for almost all tank designs q Integrated carbon canister (optional) q Reduction of permeation
q Integrated in the flange of the fuel supply unit

or stand-alone device
DC (direct current) fuel pump to provide only the amount of fuel to the engine which is currently demanded
(optional)
q Processing of fuel level sensor signals (optional) q Integrated theft protection (optional)
134
FS
135
q Enables an EC (electronically commutated) or
q Operating ventilation q Refueling ventilation (optional) q Roll over function q Retaining vapor with integrated carbon canister
Emission Technology EMITEC
Emission Technology
136
EMITEC
137
EMITEC Emission Technology
Emitec: A brief company profile

Emitec Gesellschaft fr Emissionstechnologie mbH, a joint venture between international automotive suppliers Continental and GKN Driveline, was founded in 1986. Today, the company is a world leader on the metal substrate market for exhaust gas catalysts and metallic diesel particulate filters for vehicles and mobile machinery. Complete SCR systems round off this product range. Since its foundation Emitec has sold more than 100 million metal substrates of the highest quality with excellent operating report: zero field failures. With its own development and test centre, Emitec has been partner of the automotive and engine industry regarding product and system developments for many years. The company employs around 1000 people in Lohmar and Eisenach, Germany, in Longeville-ls-Saint-Avold, France, at the Fountain Inn plant in South Carolina, 138
USA, at the plant in Pune, India and at several application engineering offices around the world. Development centres are based in Lohmar, Eisenach and Denmark. Emitecs most important markets are in Europe, North America and Asia. The company has subsidiaries in China, Japan and Korea. The companys customers include the major car, truck and motorcycle manufacturers from across the world as well as in the non-road sector producers of tractors, agricultural machinery, construction equipment, ships and diesel locomotives. Emitec owns over 1,800 patents worldwide, a fact that reflects the companys innovative strength.
EMITEC
139
METALIT (3-Way-Cat)
NO X-Adsorber
Leading metallic substrate technology Technical Information
NOX-adsorption catalysts: Technology for lean-mixture Otto-DI and Diesel engines Technical Information
q Low heat capacity for quick light-off q Foil thicknesses from 20 up to 110 m q Structured foils for enhanced efficiency
are possible
q Capacity and regeneration are important for

overall efficiency and fuel economy
q High cell densities help to improve mass transfer

and therefore conversion efficiency
q Cell densities 50 up to 1600 cpsi
q Enhanced functionality due to included

NOX Sensor increases safety margin
140
EMITEC
141
q Additional storage volume after the sensor
Pre Turbo METALIT TM
Compact Cat
Excellent Cold Start Performance Technical Information
Compact design for close coupled applications with optimized heat management Technical Information
q Use of higher exhaust gas temperature q Increases HC/CO efficiency (turbulent flow) q Reduces the needed Diesel Oxidation Catalyst
volume
q Compact design for close coupled applications

especially for Diesel applications
q Mounted directly to the turbocharger for

fast light-OFF
q Significant system cost reduction possible

(Preturbo Catalyst + Diesel Oxidation Catalyst)
q High efficiency due to optimized heat management q Potential for cost savings by volume reduction
142
EMITEC
143
PM-METALIT
SCRi -System
Partial flow deep bed filter for ultrafine particulate matter Technical Information
Catalyst system with integrated particle reduction and turbulent substrates Technical Information
q Particulates are deviated in the shovel and

deposed in the fleece layer
q Future filter strategies have to be adapted to

changing particulate sizes
q In conjunction with NO2 from the oxidation

catalyst continuous particle reduction
q Continuously working particle system without

regeneration
q Side-flow system guarantees discruption-free

engine operation through deep-bed filtration
q Above-average elimination in smallest particles q High performance reduction catalyst turbulence
q EU 4/ 5 without urea
144
EMITEC
145
generating LS/PE-Design with optimized coating allows volume reduction
LS-Design
PE-Design TM
Turbulent Catalyst Technical Information Longitudinal Structure Design
Turbulent Catalyst Technical Information Perforated Metal Foil Design
q Reduction of material / weight q Improvement of cold start performance q Increased mass transfer q Catalyst efficiency
q Lower backpressure q Faster light off q Improved turbulent mass transfer
146
EMITEC
147
Selective Catalytic Reduction SCR
Tank-integrated Dosing System Technical Information

Urea Injection
Air Assisted Dosing System Technical Information

Urea Injection
q Compact design q Stainless steel q Central heating q Pressure release instead of system purging
q Air assisted dosing system q Capacity up to 8 l/h q Simple one-hole nozzle q OEM version q Standalone system for retrofit
148
EMITEC
149
Airless Dosing System Technical Information

Urea Injection
Digital Dosing System Technical Information

Urea Injection
q Airless dosing system q Capacity up to 8 l / h q Nozzle air / water cooled q OEM version
q Dosing pump up to 960 l / h q Both airless / air assisted version q Full range of nozzles q High precision at both low and high flow
150
EMITEC
151
Continental Automotive GmbH Siemensstrasse 12 93055 Regensburg Germany Phone + 49 941 790 - 0 Fax + 49 941 790 -14 www.continental-corporation.com
Printed in Germany 08/2011 EN 6.0 k
The information provided in this brochure contains only general descriptions or performance characteristics, which do not always apply as described in case of actual use or which may change as a result of further development of the products. This information is merely a technical description of the product. This information is not meant or intended to be a special guarantee for a particular quality or particular durability. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. We reserve the right to make changes in availability as well as technical changes without prior notice. Continental Automotive GmbH

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Powertrain Products

Benefits and Technical Information

Our road to sustainable mobility

70 Sensors & Actuators S & A 72 72 73 74 75 76 77 78 79

128 Fuel Supply FS

136 Emission Technology EMITEC

Gasoline Piezo Stratified Turbo Direct Injection System

Gasoline Solenoid Turbo Direct Injection System Euro 6

Gasoline Port Injection System Flex Fuel

Diesel Piezo Common Rail Injection System

Diesel Particulate Filter

ECU Gasoline Solenoid Direct Injection

ECU Gasoline Solenoid Direct Injection NAFTA

q Engine Control Unit for Gasoline Solenoid Direct

q Engine Control Unit for Gasoline Solenoid

q Standardized, scalable and modular electronic

q Chassis mounted q Supporting Euro 5, SULEV

q Core q Flash size q Interfaces

TC1797, 150 MHz 3 MB 3*CAN, 1*Flexray, 1*Lin

ECU Gasoline & TCU Solenoid Direct Injection

EMS 3 Engine Management System Platform

q Engine Control Unit for Gasoline Solenoid Direct

TC1767, 80 MHz TC1766 2 MB 1*CAN, 1*LIN 4 SDI 46 + 2 H-Bridges IPX9K 196

ECU Gasoline Port Injection

ECU Gasoline Easy-U Port Injection

q Engine Control Unit

q Ready-to-use Gasoline Engine Management

TC1738, 80 MHz 1.5 MB 1*CAN 3 or 4 MPI 27 IPX9K 115 yes

ECU Diesel Piezo Common Rail

ECU Diesel Light Duty Engines

q Engine Control Unit for Diesel Piezo Common Rail

q Engine Control Unit for Light Duty Vehicle

q Standardized, scalable and modular electronic

q Chassis mounted q Supporting Euro IV and Euro V

q Core q Flash size q Interfaces

TC1797, 180 MHz 4 MB 2 * CAN

Freescale MPC5566, 80 MHz 24 MB 4 MB 2*CAN 4 20 + 2 H-Bridges 154 25

ECU Platform for Commercial Vehicles

ECU Diesel Heavy Duty Engines

q Diesel engine management for Amplified

TriCore TC1796 1.5 MB 3*CAN 12 21 + 1 H-Bridge IP69K IP67 141 27

ECU Aftertreatment Control

Gasoline High Pressure 1-Piston Pump

q Cost optimal design for control of exhaust

q Dry run capability q Mounted on top

MPC543 Coral 1 MB 2*CAN, 1*SAE J1708 2 19 62

Diesel High Pressure 1-Piston Pump

Diesel High Pressure 3-Piston Pump

q Designed for the

up to 2,200 bar 0.4 cm3/rev 4,500 rpm 2,000 N < 2.4 kg

Gasoline Piezo Injector

Gasoline DI XL2 Solenoid Injector

q Very fast & precise injection

q Improved linear flow range for turbocharged

q High flexibility of spray characteristics to meet the

q O-Ring or metal-to-metal sealing

q System pressure q Working flow range q Static flow q Dynamic flow

q System pressure q Working flow range q Static flow range

40 up to 150 bar up to 20 5 up to 17 g/s (at 100 bar at 70C)

Gasoline DI XL3 Solenoid Injector

Gasoline Deka VII Fuel Injector

q Improved linear flow range for high-turbocharged

q System pressure 1 up to 6 bar q Fuel compatibility Gasoline & Flex Fuel

TC1797, 150 MHz 3 MB 3CAN, 1Flexray, 1*Lin

TC1767, 80 MHz TC1766 2 MB 1CAN, 1LIN 4 SDI 46 + 2 H-Bridges IPX9K 196

MPC543 Coral 1 MB 2CAN, 1SAE J1708 2 19 62