Powertrain Products ’0 9 Benefits and Technical Information
Powertrain Products
Mobility and nature in harmony 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 pa rtner of the automot automotive ive industry, in dustry, the d ivision 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 & electric drives.
Content Passenger Car Appli cation
System Overview 8 Gasoline Piezo Piezo Stratified Direct Injection 10 Gasoline Solenoid Solenoid Direct Injection 12 Gasoline Port Injection – Flex Fuel 14 Diesel Piezo Common Common Rail Injection
16 Engine Systems – ES 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
2
Light and/or Medium, Heavy Duty Commercial Vehicles Appli cation
Diesel Piezo Common Common Rail Injector Diesel New Generation Injector Diesel High Pressure Pressure 2-Piston 2-Piston Pump ECU Diesel Piezo Common Rail DEKA SCR SCR Injector DEKA Injector for Diesel Dosing Dosing into Exhaust Gas Gasoline Piezo Piezo Injector Gasoline DI XL2 Solenoid Injector Gasoline DI XL3 Solenoid Injector Gasoline DEKA VII Fuel Fuel Injector Gasoline High Pressure Pressure Single-Piston Single-Piston Pump Gasoline High Pressure Pressure Multi-Piston Multi-Piston Pump Gasoline Turbocharger ECU Gasoline Piezo Direct Direct Injection ECU Gasoline Solenoid Solenoid Direct Injection Injection Engine Control Control Unit Gasoline Gasoline Easy-U 3
Powertrain Products
Content
34 35 36 37 38 29
Engine Systems – ES
60 Sensors & Actuators – S & A
Light Duty ECU ECU for Emerging Markets Light & Medium Duty ECU for Emerging Emerging Markets ECU for Light & Medium Duty Applications Medium & Heavy Duty Motor Control Module ECU for Heavy Duty Applications Applications Control Unit Unit for Exhaust Gas Gas Aftertreatment
62 Actuators
40 Hybrid Electric Vehicle – HEV 42 43 44 45 46 47
Power Electronics Modular Li-Ion Energy Storage System High Voltage Voltage Electric Motor Motor High Voltage Voltage Side-Mounted Starter Generator Generator High Voltage Voltage Axel Drive System System 14V Modular Power Net System
48 Transmission – TR 50 51 52 53 54 55 56 57
Mechat ronic Transmission Module Electro-Hydraulic Control Control Module Control Unit for Double Clutch Transmissions External Exter nal Transmission Control Unit Transfe ransferr Case Control Unit All-Wheel Drive Control Control Unit Unit East TCU TCU Platform Transmis sion Control Unit for Commercial Vehicles 58 Exter External nal Transmission Control Unit for Commercial Vehicles 4
62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
Air Control Control Valve Valve (ACV) Canister Purge Solenoid (CP S) Digital Linear Actuator for Idle Control Control Valve Valve Digital Linear Actuator for Idle Control Control Valve Valve Electronic Throttle Control Control Exhaust By-pass Valve Valve (EBV) Exhaust Control Valve (ECV- 3) Exhaust Control Valve Low Pressure Pressure Exhaust Throttle Valve General Purpose Actuator (GPA) Linear Purge Purge Valve Valve (LPV) Mini Electric EGR (EEGR ) Natural Vacuum Vacuum Leak Detection (NVLD II) Smart Air Control Control Valve Valve (Smart ACV) Smart Coolant Coolant Pump Pump (SCP) Transmission Oil Pump (TOP) Variable Valve Valve Train Train Actuator (Brushless DC ) Variable Valve Train Actuator
80 Sensors 80 81 82 83 84 85 86
Door Fluid Fluid Fluid Fluid Fluid Fluid
Handle H andle Sensor Sensor Level – Oil Level Switch Level Sensor Sensor – Active Electrothermic Electrothermic Level Sensor – Active Active QLT QLT Level Sensor Sensor – Active Ultrasonic Ultrasonic Level Sensor Sensor – Passive Electrothermic Electrothermic Quality – Flex Fuel Sensor Sensor 5
Powertrain Products
Content Sensors & Ac tuators – S & A 87 In Cylinder Pressure Sensors: Glow Plug Pressure Sensor & Stand Alone Pressure Sensor 88 Knock Sensor – New Design 89 Mass Airflow Sensor 90 Position Sensor – Clutch Master Cylinder 91 Position Sensor – Contactless Angular 92 Position Sensor – Fork Linear 93 Position Sensor – Linear Contactless 94 Position Sensor – Neutral Position 95 Position Sensor – Park, no Park 96 Position Sensor – Rotary Covers 97 Position Sensor – Variable Valve Train 98 Position Sensor – 360° Angle Contactless 99 Pressure Sensor – Brake Pressure 100 Pressure Sensor – Diesel Particle Filter 101 Pre ssure Sensor – Different ial Manifold Vacuum 102 Pressure Sensor – High Pressure 103 Pressure Sensor – Manifold Absolute Family 104 Pressure Sensor – Truck Applicati on MAP 105 Pressure Sensor – Relative 106 Pressure Switches 107 Sm art NOx Sensor 108 Temperature Sensor – Coolant / Fuel/ Oil 109 Tempera ture Sensor – Cylinder Head 110 Tempera ture Sensor – High Tempera ture 111 Tempera ture Sensor – Intake Air 112 Temperature Sensor – Intake Air (High EG R) 113 Tempera ture Sensor – Outside Air
6
114
116 117 118 119 120 121
Fuel Supply – FS Modular Fuel Supply Unit EC Fuel Pump G50 D / EC Code Descript ion for Names of Fuel Pumps Modular Fuel Level Sensor with MAPPS Fuel Supply Electronics Modular Function Carrier (M FC)
122 Catalytic Converters – CC 124 125 126 127 128 129 130 131
METALIT ® (3-Way-Cat) NO X-Adsorber Pre Turbo METALIT TM Compact Cat ® PM-METALIT ® SCRi-System ® LS-Design ® PE-Design ®
7
System Overview
1
2
3
4
5
6
7
8
9
10 11
Gasoline Piezo Stratified Direct Injection System 21 22
Lambda Sensor Catalyst
No.
12
No. 1 2 3 4 5 6 7 8 9
8
13
14 15
16
17 18 19
20
Technology Mass Airflow-Sensor with integrated Temperature Sensor (Frequency Output) Turbo Speed Sensor Manifold Air Pressure Sensor Electronic Throttle Control Electrical Exhaust Gas Recirculation Valve (EEGR) Exhaust Bypass Valve Piezo Injector In-Cylinder Pressure Sensor (Optional) Single Coil Ignition with Diagnosis Feedback
10 11 12 13 14 15 116 17 18 19 20 21 22 23 24 25
23 24
25
SCR (optional LNT)
Technology Dual Variable Camphaser Active Camshaft Position Sensor Canister Purge Solenoid Low Pressure Fuel Pump (PWM-controlled) Gasoline High Pressure Pump with Flow Control Valve (Single Piston) Fuel Pressure Sensor Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Active Electrothermic Oil Level Sensor Coolant (Water) Temperature Sensor Knock Sensor Active Crankshaft Position Sensor (also with Direction Detection) Turbo Charger Linear O2 Sensor High Temperature Sensor DEKA SCR-Injector NO X Sensor 9
System Overview
1
2
3
4
Gasoline Solenoid Direct Injection System
3-Way Catalyst
5
6
7
8
9
10
20
11 12 13 14 15 16 17 18 19
No. 1 2 3 4 5 6 7 8 9 10
10
Technology Manifold Air Pressure Sensor Electronic Throttle Control Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Electrical Exhaust Gas Recirculation Valve SMART NVLD 2 Canister Purge Solenoid Fuel Supply Unit Flex Fuel Sensor (Optional) Gasoline High Pressure Pump with Flow Control Valve (Single Piston) Fuel Pressure Sensor
No. 11 12 13 14 15 16 17 18 19 20
Technology Active Crankshaft Position Sensor (also with Direction Detection) Variable Valvelift 2-step Knock Sensor Coolant ( Water) Temperature Sensor Solenoid Injector Single Coil Ignition with Diagnosis Feedback Dual Variable Camphaser Active Camshaft Position Sensor Turbo Charger Binary O2 Sensor 11
System Overview
1
2
3
Gasoline Port Injection System – Flex Fuel
3-Way Catalyst
15
4
No. 1 2 3 4 5 6 7
12
5
6
8
7
Te chnology Electronic Throttle Control Manifold Air Pressure Sensor with integrated Temperature Sensor Integrated Intake Manifold SMART NVLD 2 Canister Purge Solenoid Fuel Supply Unit Flex Fuel Sensor (Optional)
No. 8 9 10 11 12 13 14 15
9
10 11 12 13 14
Te chnology Active Crankshaft Position Sensor (also with Direction Detection) DEKA VII Multipoint Injector Knock Sensor Coolant ( Water) Temperature Temperature Sensor Ignition Coil Dual Variable Camphaser Active Camshaft Position Sensor Binary O2 Sensor
13
System Overview
1
2
3
4
5
6
7
8
9
Diesel Piezo Common Rail Injection System
Oxidation Catalyst
17 18
No.
10 11 12
No. 1 2 3 4 5 6 7 8 9
14
13 14 15 16
Technology Mass Airflow Sensor Turbo Speed Sensor Air Contro l Valve Electrical Exhaust Gas Recirculation Valve (EEGR) Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Exhaust Bypass Valve Active Camshaft Position Sensor Diese Piezo Common Rail Injector Glow Plug Pressure Sensor
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Diesel Particulate Filter
19 2 0 21 2 2
SCR (optional LNT)
19 23
24
Technology Fuel Supply Unit Diesel High Pressure Pump Fuel Pressure Sensor Engine Coolant or Cylinder Head Temperature Sensor Active Electrothermic Oil Level Sensor Knock Sensor Active Crankshaft Position Sensor (also with Direction Detection) Pre Turbo Cat General Purpose Actuator High Temperature Sensor Diesel Dosing Injector Linear/Binary O 2 Sensor Relative Pressure Sensor DEKA SCR-Injector NO X Sensor 15
Engine Systems – ES
Engine Systems ES
16
S E
17
Engine Systems – ES
Diesel Piezo Common Rail Injector
Diesel New Generation Injector S E
High speed piezo actuator for a faster & more flexible injection control q Extra fine fuel atomization & minimized pressure loss in the hydraulic system q Excellent multiple injection accuracy & lifetime stability even for smallest quantities q
q Excellent
multiple injection stability due to needle direct drive and needle c losed loop control q Reduced CO2 emissions q Fulfill future emission standards Euro 6/US Tier 2 q Piezo inline design for optimized injector packaging q Outstanding low noise (NVH)
Technical Infor mation
18
Technical Infor mation
q
Pressure
up to 2,000 bar
q
Min. quantity with quantity drift correction
0.80 mm 3 0.65 mm 3
q
Max. no. of injections
7
q Max.
q
Min. injection separation
100 µs
q Min.
injection separation
no hydraulic dwell
q
Continuous leakage
35 ml /min
q Total
leakage
10 ml / min
q
Diameter nozzle holes
> 90 µm
q Diameter
q Pressure
2,000 bar and above
q Min.
0.65 mm 3 /shot
quantity no. of injections
nozzle holes
7
> 90 µm 19
Engine Systems – ES
Diesel High Pressure 2-Piston Pump
ECU Diesel Piezo Common Rail S E
Minimized pump leakage for reduced fuel consumption and CO 2 emissions q Weight and package optimized high pressure pump q
Technical Infor mation q
Pressure
up to 2,000 bar
q
Displacement
0.596 up to 0.795 cm 3 /rev
q
Piston (max. Ø)
7.5 mm
q
Stroke (max. )
9 mm
q
Max. speed at full load 4,000 rpm
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 Technical Infor mation q Core q Flash
TC1796, 150 MHz size
q Interfaces q Injection q Driver
20
CAN bus: 1 incl. wake up
drivers 4, single bank
outputs
q Housing
2 MB
24 sealed IP5k9k, connector 154 pin 21
Engine Systems – ES
DEKA SCR Injector
DEKA Injector for Diesel Dosing into Exhaust Gas S E
Optimized design for airless SCR dosing systems Reliable delivery of urea with excellent spray performance q Frost-proof ( no emptying of dosing system at shutdown) q Part of Continental’s approach to SCR systems q q
q Robust
approach for Diesel Particle Filter (DPF) regeneration q Avoidance of oil dilution by post injection q Uses existing injection technologies q Improved fuel economy Technical Infor mation
Technical Infor mation q
22
Nominal flow
q Nominal
Qs = 1.7 g /s, Qd = 3.8 mg/ stroke (5 bar, AUS32 )
q
Fluid pressure range
3.8 up to 7.5 bar
q
Sauter Mean Diameter (SMD)
< 75 µm (5 bar, AUS 32)
q
Injector spray type
Cone / 42° cone angle
q
Max. injector temperatures 120°C (injector body) >180°C (injector tip)
q Input
flow
pressure range
q Sauter
Qs = 2 up to 6 g /s, Qd = 20 mg/ stroke 3.5 up to 8 bar
Mean Diameter (SMD ) 50 up to 100 µm (n-heptane)
q Accura cy
of flow
+/ – 6 %
q Max.
control valve temp.
120°C
q Max.
spray nozzle temp.
600° C
q System
minimum pulse width 10 ms 23
Engine Systems – ES
Gasoline Piezo Injector
Gasoline DI XL2 Solenoid Injector S E
q Very
fast & preci se inje ction (up to 4 injections/combustion cycle) q Extended linear flow range, high flow capability q World wide fuel compatibility Technical Infor mation
24
q Improved
linear flow range for turbocharged engines q World wide fuel compatibility q High flexibility of spray characteristic to meet the requirements of each target engine q O-Ring or metal-to-metal sealing
q
System pressure
50 up to 200 bar
q
Working flow range
> 50
q
Static flow
> 35 g/ s
q
Dynamic flow
14.5 mg / injection ± 10% at 0.4 ms PW
q
Min. dynamic flow
< 2 mg /stroke
q Min.
q
SMD size
~ 15 µm
q SMD
q
Opening/ Closing time
≥
q
Spray angle
94°/9 8° ± 4°
q
Temperature range
– 30 up to +140°C
150 µs
Technical Infor mation q System
pressure
q Working q Static
flow range
flow range
dynamic flow size
40 up to 150 bar > 20 5 up to 17 g/s (at 100 bar at 70° C) < 4 mg /stroke < 15 µm
q Opening/ Closing
min. 300 µs
q Cone
35 ° up to 90 °
q Bent
angle range angle range
0° up to 30 °
25
Engine Systems – ES
Gasoline DI XL3 Solenoid Injector
Gasoline DEKA VII Fuel Injector
Improved linear flow range for high-turbocharged engines q World wide fuel compatibility 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
q
opening/closing, various packaging options orifice configurations q Low pulse width with high linear performance and low voltage sensitivity q Flexible
Technical Information q Fuel
pressure range 1 up to 6 bar
q Fuel
compatibility
Technical Infor mation
26
s n i a r t s n o c n o i t a r b i l a c n o g n i d n e p e D *
q
System pressure
40 up to 200 bar
q Static
q
Working flow range
> 24*
q SMD
q
Static flow range
> 20* g /s
q
Min. dynamic flow
< 3* mg/ stroke at 40 bar
q
Max. functioning pressure 260 bar
q
Multiple injection
< 500 µs dwell time
q
Multi-stream technology
max. 8 holes
q
Family layout
short, long, extended
(at 100 bar at 70°C )
flow rate
size
q Opening q Closing q Min.
time
time
linear pulse
q Possible
spray patterns
Gasoline & Flex Fuel (up to E100) per applic. 0.95 up to 6.0 g /s ~ 60 up to 100 µm 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 3 0°
27
Engine Systems – ES
Gasoline High Pressure Single-Piston Pump
Gasoline High Pressure Multi-Piston Pump S E
q
q World
q
World wide fuel compatibility Low friction due to running components in permanent oil filling q Dry run capability q Mounted on top of the camshaft
q Low
wide fuel compatibility friction due to running components in permanent oil filling q Dry run capability Technical Infor mation
Technical Infor mation q
Max. fuel pressure
q Supply pressure
28
q Max.
up to 200 bar 4.5 up to 6 bar
q
Temperature range
– 40 up to +130°C
q
Control
flow controlled
q
Drive
cam driven
q
Integrated (inlet ) flow
control valve
fuel pressure
q Supply
pressure
q Temperature
range
up to 200 bar 4.5 up to 6 bar – 40 up to +130°C
q Control
flow controlled
q Drive
end of camshaft or belt driven
q Maximum
flow
up to 240 l/ h ( at 3500 rpm, depending on the # of pistons 2 up to 6)
q Integrated
(inlet) flow control valve 29
Engine Systems – ES
Gasoline Turbocharger
ECU Gasoline Piezo Direct Injection S E
q Designed
for a fully integrated robotized assembly process q Outstanding thermodynamics q Robust and reliable design Technical Infor mation q Gasoline
application up to 1050 °C exhaust gas temperatures
q Engine
power
up to 90 kW per Turbo
wheel Ø
30 up to 39 mm
q Turbine q Air
flow
max. 0,1 kg/s
q Speed
max. 330,0 00 rpm
q Integrated q Electric q Milled
30
recirculation valve
actuated wastegate control
q Engine
Control Unit for Gasoline Piezo Direct Injection q Standardized scalable and modular electronic hardware q Engine compartment, option for water cooling q Supporting Euro 5 Technical Infor mation q Core q Flash
TC1796, 150 MHz size
q Interfaces q Injection q Driver
BSD, LIN-Bus, FlexRay, 2* CAN
drivers 8
outputs
q Housing
2 MB, optional 2 MB external
32 sealed, IP6K4K, connector 177 pin
compressor wheel 31
Engine Systems – ES
ECU Gasoline Solenoid Direct Injection
Engine Control Unit Gasoline Easy-U
Engine Control Unit for Solenoid Direct Injection Standardized and modular electronic hardware q Chassis mounted q Supporting Euro 5
q Ready-to-use
q q
Technical Infor mation
Gasoline Engine Management System for worldwide applications: Europe low budget vehicle segment, Russia, China, India, ASEAN, Middle East, South America q Modular and scalable system approach to cover various engine and vehicle configurations including Euro 5 and EOBD
q
Core
TC1796, 150 MHz
q
Flash size
2 MB + 2 MB external
Technical Infor mation
q
Interfaces
Lin, 2* CAN
q ECU
q
Injection drivers 6 (8 optional)
q Core
q
Driver outputs
32
q Flash
q
Housing
sealed, IP6k9, connector 154 pin
with predefined set of sensors and actuators Coral, 40 MHz size
q Interfaces q Injection q Driver
32
1*CAN, 1*K-line
drivers 4 MPI
outputs
q Housing
1 MB
20 sealed, IPX7, connector 32 + 64 pins
33
Engine Systems – ES
Light Duty ECU (Emerging Markets)
34
Light & Medium Duty ECU (Emerging Markets)
q
Engine Control Unit for Light Duty Vehicle Applications q Chassis mounted q Supporting Euro IV
q Engine
Control Unit for Light & Medium Duty Vehicle Applications q Cab mounted q Supporting Euro III, IV
Technical Infor mation
Technical Infor mation
q
Core
Freescale MPC5566 (UIPER )
q Core
Freescale MPC5 55
q
Clock frequency
80 MHz
q Clock
q
Flash size
24 MBit
q CAN
q
RAM
4 MBit
q Injection
q
CAN BUS
2
q Driver
q
H-Bridges
2
q Connecto r
q
Injection drivers
4
q
Driver outputs
20
q
Connector pins
154
frequency
BUS
40 MHz 2
drivers
outputs pins
6 15 121
35
Engine Systems – ES
ECU for Light & Medium Duty Applications
Medium & Heavy Duty Motor Control Module S E
Engine Control Unit for Piezo Common Rail and Amplified Common R ail Inje ction S ystems q Engine mounted with dampers q Supporting EPA 07 q
q Motor
Control Module for Common Rail, Amplifie d Common Rail an d Pump-L ine-Nozzle Injection Systems q On-engine mounted with damping elements q Supporting Euro VI, EPA 10
Technical Infor mation q
Core
Green Oak
q
Flash size
16 Mbit
q
RAM
32 kB
q
CAN BUS
2
q
H-Bridge output
up to 2
q
Injection drivers
up to 8
q
Connector pins
2 x 76; 1 x 36
Technical Infor mation q Core
TriCore TC1766
q Flash q CAN
size
BUS
3
q H-Bridge
output
1
q Injection
drivers
12
q Driver
outputs
q Connector
36
1,5 MB
pins
21 1 x 120; 1 x 21
37
Engine Systems – ES
ECU for Heavy Duty Applications
38
Control Unit for Exhaust Gas Aftertreatment
q
Engine Control Unit for high pressure Solenoid Injection System q On-engine mounted w/o damping elements q Supporting Euro V w/o SCR
q Control
Unit for Selective Catalytic Reduction (SCR) q Chassis mounted q Supporting Euro IV, V
Technical Infor mation
Technical Infor mation
q
Core
Green Oak
q Core
16 bit
q
Flash size
2.5 MB
q Clock
q
RAM
2 Mbit
q CAN
q
CAN BUS
3
q Ubat
q
H-Bridge output
2
q Connector
q
Injection drivers
8
q
Connector pins
14 x 10
frequency
BUS
20 MHz 1 12/24 V
pins
62
39
Hybrid Electric Vehicle – HEV
Hybrid Electric Vehicle HEV
40
V E H
41
Hybrid Electric Vehicle – HEV
Power Electronics
Modular Li-Ion Energy Storage System
New Generation Power Electronics
Single Inverter
V E H
Single DC/DC Converter
q q
Modular design Control module for electric machine in hybrid electric vehicle, electric vehicle and fuel cell vehicle
q Applica tion
in hybrid, electr ic and fuel ce ll vehic les and lifetime optimized cells q Synergy effect through modular system q Variable c ooling sy stem q Safety
Technical Infor mation q
Water cooling
Inverter q
Power: up to 150kW at 450V
q
Converts energy in both directions – drive electric machine in motor and generator mode
Converter
42
q
Power: up to 3kW
q
Bi-directional potential free energy transport between HV traction battery and 14V power net
q
Replaces conventional 14 V generator
Technical Infor mation q Power: q Li-Ion
18 kW –120 kW
ultra high power cells
q Integrated
battery management
q Integrated
safety system
q Integrated
cooling system
43
Hybrid Electric Vehicle – HEV
High Voltage Electric Motor
HV Side-Mounted Starter Generator
V E H
In cooperation with ZF
q
q High
q
Pure electric driving (zero emission) Permanent synchronous or induction machine q Transmission integrated
q High
Technical Infor mation
speed asynchronous machine power density q High efficiency q Low weight q Short axial length q Cost-optimized
q
Operates
up to 450 V
q
Power
up to 75 kW
Technical Infor mation
q
Fast start
< 300 ms
q High
speed
up to 18000 rpm
q
Cold start
< 800 ms
q High
voltage
up to 150 V
q
Speed
up to 7.000 rpm
q Regenerative
Power
5 kW continuous, 20 kW peak
q Water-cooling q Aluminium q Special
44
housing
stator winding design 45
Hybrid Electric Vehicle – HEV
High Voltage Axle Drive System
14V Modular Power Net System
V E H
High speed synchronous machine (external excited) q High power density q High efficiency q Cost-optimized q
Technical Infor mation q
High speed
q High voltage q
Regenerative power
q
Water-cooling
q Aluminum q
46
up to 12,000 rpm up to 450 V 35 kW continuous, 70 kW peak
h ousing
Mechanical integration gear/e-machine
q Energy
storage for limited regenerative braking (up to 4% CO 2 reduction) q Provides second voltage level for high power applications q Support of start-stop q High number of load cycles q Modular and integrated designs available Technical Infor mation q DC/DC
converter 0,4k W 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 – Based on Double Layer Capacitors – Includes active or passive balancing q Energy management & diagnosis (e.g. SOC, SOH) q CAN or LIN communication
47
Transmission – TR
Transmission TR R T
48
49
Transmission – TR
Mechatronic Transmission Module
Controls 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
Electro-Hydraulic Control Module
q Controls
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
R T
Technical Infor mation
50
q
E-Module based on flex technology
q
Position, speed and temperature sensors integrated
Technical Infor mation q Operating q 32-bit
temperature –40° C up to +140°C
processor with external flash memory
q
LTCC (Low temperature co-fired ceramics ) substrate for electronic components
q Low
temperature co-fired ceramics ( LTCC) substrate for electronic components
q
Temperature range from – 40°C up to +143°C
q 14-pin
q
Powerful 32 bit microcontroller
q Communication
q
Communication via CAN bus
vehicle interface connector system via CAN bus
51
Transmission – TR
Control Unit for Double Clutch Transmissions
Controls 7-speed dry double clutch transmission q Integration of all transmission sensors into the control unit q Higher reliability of the electronics due to the reduced number of internal connections q Weight reduction due to integration
q Controls
Technical Infor mation
q Communication
q
52
External Transmission Control Unit
q
Direct connection of actuators to the c ontrol unit
q
Only one plug connection to the vehicle
q
Control of BLDC motor of oil pump
q
Operating temperature range – 40°C up to +140°C
q
Maximum permissible acceleration
q
32 bit processor
5-speed automatic transmission q Stand-alone concept q Control of 6 valves
R T
Technical Infor mation q 16
bit processor via CAN-Bus
q Power
outputs for 6 electromechanical hydraulic valves: – 2 control valves for the hydraulic of the transmission – 3 control valves for the gear changing – 1 valve for bypass converter
53
Transmission – TR
Transfer Case Control Unit
All-Wheel Drive Control Unit
q
Controls high/low shift and a ctive torque distribution of transfer cases used in Four-Wheel-Drive vehicles q For improved traction on-road and off-road
q Controls
the torque distribution of All-Wheel-Drive vehicles by actuating a limited slip coupling q Directly attached to All-Wheel-Drive coupling device
Technical Infor mation
Technical Infor mation
q
Powerful 16 bit processor
q Powerful
q
Flame Retardant 4 (FR4) substrate for electronic components
q Flame
q
Power output for one actuator motor
q Power
q
Protection class IP40
q Protection
q
Communication via CAN bus
q Communication
q
Stand-alone housing with integrated cooling plate
q Operating
temperature up to 120°C
q
Operating temperature up to 85°C
q Integrated
connectors for solenoid and pressure
R T
16 bit processor
Retardant 4 (FR4) substrate for electronic components outputs for one valve and feeder pump class IP 6K9K via CAN bus
sensor 54
55
Transmission – TR
East TCU Platform
Controls of stepped AT, CVT, DCT, hydraulic AMT q Stand alone concept q Reduced time-to-market thanks to existing platform q Cost efficient solution q
Technical Infor mation
Transmission Control Unit for CV
q Controls
6-speed automatic transmission q Control unit for retarder truck 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
Environment: engine or passenger compartment
q
32-bit Microcontroller with internal flash memory
Technical Infor mation
q
Flame retardant FR4 printed circuit board substrate
q Ceramic
q
State of the art input/ output stages
q IP6k9
q
Communication via CAN-Bus
q 32
bit microcontroller
q
Start of production in 2009
q 24
V/12 V capable
substrate and direct copper bonded technology housing with overmolded leadrame
q Temperature:
56
R T
q2
– 40°C up to +140°C
x Can Bus and current control outputs (10)
57
Transmission – TR
External Transmission Control Unit for CV Development of transmission control units.
Controls 6-speed automatic transmission q External control unit q Improved shift comfort q Reduced life cycle costs q Higher reliability q
R T
Technical Infor mation
58
q
Powerful 32 bit processor
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
Operating temperature up to 105°C
59
Sensors & Actuators – S & A
Sensors & Actuators S&A
A & S
60
61
S & A Actuators
Air Control Valve (ACV)
Non-contacting MR sensor not sensitive on environmental influences q Version with plastic housing l ighter t han alum inium q Version with electroni cs ea sy to in tegrate in existing ECU q
Canister Purge Solenoid (CPS)
q Canister
regeneration with a PWM solenoid flow curve, sonic nozzle flow control q Fast response, light weight, compact size q Various moun ting opti ons ava ilable q Direct manifold mount with NVH suppression feature q Linear
Technical Information q
q
62
Operating temperature range
– 40 up to +125°C (up to +160°C on specific designs)
Intake manifold air pressure (absolute)
100 up to 2500 hPa (up to 3500 hPa on specific designs)
q
Response time
< 150 ms (< 100 ms on spec. designs)
q
Excess torque
> 1.0 Nm (> 1.6 Nm on spec. designs)
A & S
Technical Information q Flow
at 500 mm Hg
q Nominal q Coil
operating voltage
resistanc e
q Control
circuit
50 up to 85 SLPM 14 VDC 17 Ohms PWM
q Operating
frequency
5 Hz up to 32 Hz
q Operating
temperature
– 40 up to +140°C
q Total
leakage at 500 mm Hg
q Sonic
< 20 SCCM
regulated above 100 mm Hg
63
S & A Actuators
Digital Linear Actuator for Idle Air Control Valve
Digital Linear Actuator for Idle Air Control Valve
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
q The
Technical Information
Technical Information
q
64
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
q
Operati ng Voltage
12 V (7.5 V/14 V)
q Operating
q
Inductance per winding
38 mH
q Inductance
per winding
33.5 mH
q
Resistance per winding
48 Ohms
q Resistance
per winding
53 Ohms
q
Resolution
0.04167 mm / step
q Resolution
0.04167 mm / step
q
Total travel
9.35 mm (224 steps)
q Total
8.5 mm (204 steps)
q
Operating temperature
– 40 up to +150°C
q Operating
q
Weight
90 g
q Weight
110 g
35 up to 40 G
q Vibratio n
35 up to 40 G
q Vibration
Voltage
travel temperature
A & S
12 V (7.5 V/14 V)
– 40 up to +125°C
65
S & A Actuators
Electronic Throttle Control
Non-contacting MR sensor not sensitive on environmental influences; can be used in close proximity e.g. to alternators q Version with plastic housing l ighter a nd with better crash performance than aluminium q
Technical Information q
Operating temperature range – 40 up to +125°C
q
Storage temperature range
q
Intake manifold air pressure Plastic housing 100 up to 2500 hPa (absolute) Aluminum housing 100 up to 3000 hPa (absolute)
– 40 up to +140°C
q Typical response time ( t 90, room temperature) Plastic housing < 130 ms Aluminum housing < 90 ms q
66
Excess torque Plastic housing > 1.0 Nm Aluminum housing > 2.0 Nm
Exhaust By-pass Valve (EBV)
q Design
options available to fit c ustomer requirements q Easy integration into EGR cooler q Flexible housing design q Leakage to atmosphere < 0.5 kg/h at 3 bar q Internal MR sensor for position accuracy within 2° q Max. DC motor current draw 6 A, running current 2 A typ.
A & S
Technical Information q Operating
ambient temperature range
q Exhaust
gas temp.
– 40 up to +140°C 600°C (short term 650 °C )
q Actuato r
openin g – design capability range 100 ms up to 1000 ms
q Mechanical
closing – design capability range 100 ms up to 1000 ms
q Noise
level
< 60 dB
67
S & A Actuators
Exhaust Control Valve (ECV-3)
Exhaust Control Valve Low Pressure
Provides both accurate low flow precision (improves engine performance) and high volume flow (improves emission reduction) by maintaining low gas pressure drop q Contactless MR sensor, flexible output, not sensitive against magnetic fields, well known control strategy q Compact, light weighted size and water c ooled additional shaft bearing to withstand high pressure pulsation
q Provides
q
Technical Information
68
q
Torque at flap: 230 Ncm
q
Response time (85%): < 80 ms
q
Nominal supply voltage: 13.5 V
q
Position sensor supply voltage: 5.0 V
q
Maximum flow: up to 190 kg/h at 50 hPa
q
Exhaust temperature: up to 700°C
both accurate low flow precision (improves engine performance) and high volume flow (improves emission reduction) by maintaining low gas pressure drop q Contactless MR Sensor, flexible output, not sensitive against magnetic fields, well known control strategy q Compact, light weighted size and water cooled
A & S
Technical Information q Nom.
supply voltage: 13.5 VDC
q Position
sensor supply voltage: 5.0 VDC
q Maximum
flow: up to 350 kg/h at dp 50 hPa
q Valve
sea t leak age: max. 1,5 kg / h at d p 60 0 hPa
q Max.
differential pressure over flap: 600 kPa
q Max.
backpressure (p3): 900 kPa
q Exhaust
gas temperature: max. 500°C, permanent 400°C
69
S & A Actuators
Exhaust Throttle Valve
Resistant to external aggression: stone projection, gravel, water splashes… q Resistant to corrosion using specific materials, i.e. flap housing off precision casting or welded stainless steel technology q Existing serial proven actuator portfolio q
Technical Information
70
General Purpose Actuator (GPA)
q Continuous
position control of intake flap and turbo charger applications q More precise and independent from vacuum based systems q Version with electroni cs eas y to in tegrate in existing ECU Technical Information
q
GPA technology used f or actuation
q
Nominal supply voltage: 13.5 VDC
q
Position sensor supply voltage: 5.0 VDC
q Various
q
Maximum flow: up to 420 kg/h at dp 50 hPa
q Worm
q
Response time – Valve opening: < 100 ms (from 0 % to 85 % of max. opening angle) – Valve closing : < 100 ms (f rom 0 % to 15 % of max. opening angle)
q Return
q
Exhaust gas temperature: 800°C
A & S
q Available
as version with integrat ed ele ctronics, or position control sensor mot or sizes availa ble
gear or spur gear spring for self return functionality
q Typical
data for M-28 GPA at room temperature and 13.5 V: – Response time (for t90 and 90° travel) 130 ms – Stall torque 140 Ncm – Continuous output torque 55 Ncm
71
S & A Actuators
Linear Purge Valve (LPV)
Mini Electric EGR (EEGR)
Canister regeneration with a linear proportional solenoid q Very low oper ating noise due to constant current input 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 Electric
Technical Infor mation
q Current
q
72
q
Typical flow
70 SLPM at 57 kPa
q
Operating voltage
14.0 VDC
q
Coil resistanc e
14.0 Ohms
q
Maximum current
500 mA
q
Control circuit
Constant current at 150 up to 200 Hz
q
Weight
200 g
Actuation has faster response and more control than conventional vacuum systems q Eliminates vacuum regulator and connecting hoses q Can be tailored to customer flow requirements Technical Information q Nominal
operating voltage
consumption at max flow
q Max
current consumption
A & S
13.5 VDC 1.0 A at 20° C 1.5 A
q Nominal
coil resistance
8.0 Ohms at 20°C
q Nominal
operating frequency
90 Hz up to 175 Hz
q Position
sensor supply voltage 5.0 VDC
q Response
time (total stroke) < 50 ms (open to close or close to open) 73
S & A Actuators
Natural Vacuum Leak Detection (NVLD II)
Smart Air Control Valve (Smart ACV)
With Integrated Electronic (NVLD II integrated) Diagnostic performed after key off q Stand-alone or canister mounted versions q Temperature sensing; Switch sensing q Timer function
q Improves
q q
Technical Information q Vacuum
sensi ng switc h with – 2.5 ± 0.3 mba r calibration
q
Damping feature to avoid noise
q
Weight approx . 100 g
q
Bit serial communication with ECU
q Average q
74
current c onsumption < 50 µA
High In Use Monitor Performance Ratio (IUMPR > 100%)
EGR-function by increased and/or more exact EGR-ratio under all driving conditions. Helps to meet exhaust gas legal requirements q Avoids ty pical d iesel engine v ibration during engine shut-off by closing the air channel q Easy to integrate into existing engine management system related to simple communication
A & S
Technical Information q Integrated
control unit with processor and H-bridge for DC motor on-board
q Aluminum
housing a nd throttle plate
q Non-contacting q Temperature
position sensor
range
time (full stroke, RT)
– 40 up to +125°C
q Response
< 150 ms 75
S & A Actuators
Smart Coolant Pump (SCP)
q Precise
engine temperature control through variation of coolant volume flow q Operation independent from engine for fuel economy, comfort, and advanced propulsion applications
q Continental
Technical Information
Technical Information
q Electronically
q EC-Motor;
q Integrated q Wet
commutated 12 V D C-motor
electronics in thick film technology
running permanent magnet rotor
q Volume
flow
q Differential q Hydraulic q Supply
pressure
power
current at Pmax
q Coolant
76
Transmission Oil Pump (TOP)
900 0 l / h 800 hPa 200 W 32 A
as system supplier for all t hree components q E-Motor and electronics from one source q Already serial production history w ith inte gration of motor, pump, and electronics in one unit
A & S
commutation with or without sensor
q Electric
power
~ 150 W up to 700 W
q Electronics
ambient temperature capabilities up to 140°C
q Available
pump typ es depending on requirements – Vane-type – G-Rotor
temperature range – 40 up to +128°C 77
S & A Actuators
Variable Valve Train Actuator
Variable Valve Train Actuator
Brushless DC Motor
Continuous positioning of eccentric shaft v alve li ft q High dynamics (low inertia) q Closed loop control via integrated position sensor q EC-motor mounted in cylinder head (small package)
q Continuous
Technical Information
Technical Information
q
q Adjusts
78
positioning of eccentric shaft to adjust valve lift q Closed loop control via separate position sensor and position control electronics q Reliable and proved concept in serial production engines
q
EC motor
M -42
q DC
Motor
q
Diameter
42.6 mm
q Diameter
60.5 mm
q
Length
70.0 mm w/o connector
q Length
91.0 mm
q
Weight
567 g
q Weight
998 g
q
Max. EC motor power
480 W
q Max.
DC motor power
355 W
q
Stall torque
70 Ncm with current limited by the ECU
q Stall
torque
215 Ncm; current limited by the ECU
q
Temperature range
– 40 up to +140°C
q Operating
A & S
M60
temperature range – 40 up to +140°C 79
S & A Sensors
Door Handle Sensor
Fluid Level Oil Level Switch
q
Easy to integrate into the door handle Low power consumption (<100 µA for double zone sensor) q Reduced false detection thanks to adaptation of environment conditions (rain, fog, snow...)
q Low
q
q Different
Technical Information
80
q
Capacitive sensor for Keyless Entry System
q
Detection distance 0 up to 40 mm
q
Response time
q
Optional: – Capacitive switch for door locking – Mechanical switch for door locking – Movement sensor – LED for ground / pocket illumination – LF antenna integration
< 5 ms up to 30 ms
oil level detection connectors possible q Simple on/off output Technical Infor mation q Measuring
principle: magnetic reed switch
q Different
switch heights possible
q Normally
on (switch closed)
q Tolerance:
A & S
± 1 mm
81
S & A Sensors
Fluid Level Sensor Active Electrothermic
Fluid Level Sensor Active QLT
QLT = Quality Level Temperature
q
Overfill and low level indication measure ment of oil lev el in static and dynamic conditions q Replacement of oil dipstick q Stand-alone sensor with integrated electronics („active“) q Temperature measurement optional
q Overfill
q Absolute
q Absolute
Technical Information
Technical Infor mation
q
Measuring principle
thermoresistive heated wire
q Measuring
principle
capacitive
q
Measuri ng range
110 mm betw. min. & max.
q Measuring
range
40 up to 120 mm
± 2 mm
q Accura cy
q Accurac y
82
and low level indication measurem ent of oil leve l in sta tic and dynamic conditions. Replacement of oil dipstick q Stand-alone sensor with integrated electronics („active“) q Oil quality information (permittivity) q Extension of the oil change intervals
± 2 mm
q
First measurement
available 0.6 s after key-on
q First
measurement available in 1.4 sec after key-on
q
Measuring interval
> 5 sec
q Measuring
q
Current consumption
200 ± 1 mA (pulse mode)
q Permittivity
q
Operating temperature – 40°C up to 160°C
q
Temperature accuracy ± 3°C
interval
~ 1 sec.
measuring range (quality) : 1 up to 6 Typical value for engine oils 2 up to 3
q Temperature
measuring range – 40 up to + 160°C
83
S & A Sensors
Fluid Level Sensor Active Ultrasonic
Overfill and low level indication measurement of oil leve l in sta tic and dynamic conditions q Replacement of oil dipstick q Stand-alone sensor with integrated electronics („active“) q Low power consumption q Temperature measurement optional q
q Overfill
q Absolute
q Absolute
Technical Infor mation q
Measuring principle
ultrasonic echo
q
Measuring range
18 mm up to 163 mm
q Accurac y
84
Fluid Level Sensor Passive Electrothermic
± 2 mm
q
First measurement available 0.3 sec after key-on
q
Measuring interval
~ 1 sec.
q
Operating temperature – Level – Temperature
– 40 up to + 160°C – 10 up to + 150°C – 40 up to + 160°C
and low level indication measurement of oil leve l in sta tic and dynamic conditions q Replacement of oil dipstick q Different mounting positions q Temperature measurement optional Technical Infor mation q Measuring
principle
thermoresistive heated wire
q Measuring
range
110 mm betw. min. & max.
q Accura cy
approx. ± 3 mm
q First
available 0.6 s after key-on
measurement
q Measuring q Current
consumpt ion
q Operating q Temp.
interval
A & S
> 5 sec max. ~200 ± 1 mA (pulse mode)
temperature – 40°C up to 160°C
measurement
optional with NTC (± 2° C)
85
S & A Sensors
Fluid Quality Flex Fuel Sensor
In Cylinder Pressure Sensors
1
2
In-line sensor mounted between fuel tank and engine q Meets OBD I I functional requirements q Allows us age of saddle tanks on flex fuel vehi cles q Provides safe car operation (no engine stall) q Active tempera ture and conducti vity co mpensat ion q Simple Compact design, proven, safe and reliable q Various conne ctor in terfac es ava ilable q
1 Glow Plug Pressure Sensor 2 Stand Alone Pressure Sensor q Easy
to integrate Allows cl osed-loop combustion control q q Reduces emissions q Increases engine power q Reduces fuel consumption q Simple and robust solution
A & S
Technical Information q
Measures Ethanol content of Ethanol/Gasoline mix
q Accurac y
86
± 5% on Ethanol
q
Frequency output based on percent Ethanol – PWM output
q
Operating temperature
– 40°C up to +125°C
q
Supply voltage
9 up to 18 V
q Maximum flow
400 l /h (80 g/s )
Technical Infor mation q Cylinder
pressure measurement during compression and combustion stroke accuracy: 3.5%
q Integrated q Active q Small
in the glow plug or stand-alone sensor
sensor size sensor: M8 thread 87
S & A Sensors
Knock Sensor – New Design
Mass Airfl ow Sensor
1 2 1 In-Tube MAF Sensor 2 Plug-In MAF Sensor
High sensitivity Compact design, nested bolt possible q Increases engine power q Decreases fuel consumption q q
Technical Infor mation q Acceler ation
se nsor ba sed on piezo c eramic technology with a range of: 0 up to 4 00 g
q
Frequency range: 3 up to 25 kHz
q
Possible integration of discharge resistor
q
Integrated connector or cable version
q High
flow measurement accuracy and exceptional signal stability q Integral protection against water and contamination q Customer specific programmable output 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 Technical Infor mation q Sensing q Flow
technology Hot-film bi-directional MEMS
range
q New-part
88
A & S
5 up to 800 kg/h (62 mm tube)
tolerance 1.5%
q Supply
voltage
5 ± 0.5 V
q Supply
current
10 mA maximum
q Output
signal
Frequency or SENT digital
q Integrated
intake air temperature sensor optional
89
S & A Sensors
Position Sensor – Clutch Master Cylinder
Position Sensor – Contactless Angular
Some mechanical interface for either dual switch or linear position sensor configuration q Small sensor package to fit in small environment q Best cost magnetic system (sensor + magnet)
q Contactless
Technical Infor mation
Technical Infor mation
q
q
Non contacting technology
q Magnetic
q
23 to 36 mm range
q Measurement
q
Dual switch (start of course, end of course) configuration (± 1 mm accuracy) or linear position sensor configuration (± 3% accuracy with possibility to reach ± 1.5% with on clutch calibration)
q Temperature
q Accurac y
q
90
sensors, no wear performance and best cost q Possible re-calibration to compensate for mechanical tolerances q High
q
q Analog,
technology range up to 360°C
range
– 40 up to 150°C
PWM or di gital output
q Through-wall
(aluminum, plastic) possible
measurement
of 3 % for linear position, ± 1 mm for switch
q Compensated
Temperature – 40° C up to – 150°C
q Stand
Magnet integrated in piston
A & S
for airgap and temperature
variations alone sensor, can include the magnet
target 91
S & A Sensors
Position Sensor – Fork Linear
Position Sensor – Linear Contactless
Measures the fork position to enable fork actuation in Dual Clutch Transmission, Automatic Transmission or Step Automated Transmission q Automatic Transmissio n Fluid compati ble de sign q Mechanical interface compatible with transmission modules q Robust and proven magnetic design
q Contactless
q
Hall effect technology
q
Operation temperature – 40°C up to 150°C
q
Supply voltage
4.5 V up to 5.5 V
q
Measurement range
23 mm
Ratiometric output
4.5 mm
q Temperature q Analog,
range from 10 mm up to 55 mm
range
– 40°C up to 150°C
PWM or digital output
q Through-wall
(aluminum, plastic) possible
measurement q Compensated
for airgap and temperature
variations q Stand
92
A & S
technology
q Measurement
q
q
Technical Information q Magnetic
Technical Information
q Airgap
sensor, no wear performance and best cost q Compact design, easily integrated q Possible re-calibration to allow better tolerances on the mechanics q High
alone sensor, can include the magnet target 93
S & A Sensors
Position Sensor – Neutral Position
Position Sensor – Park, no Park
Detects that gear lever is in neutral position to enable Stop & Start f unction with manual gearbox q Allows Sto p & Start func tion on manual gearbox to reduce fuel consumption up to 10% q Robust and proven magnetic design
q No
Technical Infor mation
q Measuring
q
q
Magnetic technology
q
Operation temperature
q Airgap q
94
Insensitive to gearbox metallic debris
– 40°C up to 150°C up to 1.5 mm
magnet used: no iron particles pollution to low frequency magnetic fields q Best cost sensor system (sensor and target) q Insensitive
Technical Infor mation q Inductive
q Signal
technology the target is a metallic plate range
output
q Temperature q Supply
range
voltage
A & S
linear: 10 mm up to 60 mm rotary: 0° up to 180° analog, PWM – 40°C up to 160°C 5V
up to 2 gr
95
S & A Sensors
Position Sensor – Rotary Covers
Air Control Valve A pplicatio n Fully integrated MR sensor in the cover High temperature q High accuracy q Ageing stability (M R technology) q Low cost design q q
Technical Infor mation q Angular r ange
96
Position Sensor – Variable Valve Train
q Sensor
assembly inclusive magnet wheel to install q Insensitive to air gap variation q Insensitive to magnet temperature coefficient q Analog and digital interface q Calibration possible q Very robust t o parasitic magnetic field q Easy
A & S
Technical Infor mation 180°
q Non-Contacting
q
Linearity
± 0.6% Vdd
q
Hysteresis
± 0.15% Vdd
q
Power supply
5V
q
Power consumption
< 10 mA
q
Magnet field requirement 50 mT
q Temperature
q
Temperature range
q Based
– 40 up to 160°C
Rotary Position Sensor
q Accuracy
± 1%
q High
0.022 °
resolution
q Programmable
measuring range
0 up to 180°
range up to 160°C
on MR technology 97
S & A Sensors
Position Sensor – 360° Angle Contactless
Pressure Sensor – Brake Pressure
Contactless rotary sensor for transmission application with programmable Hall effect technology q Full 360 ° rotation q Environmentally and electrically robust design q Electrical performance stable over temperature q Locking clip fixes rotor position for installation
q Direct
Technical Infor mation
Technical Information
q
measurement of pressure and temperature 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 Excellent dynamic response q Flexible
q
Rotational Range
360 °
q Pressure
Range
q
Total Error
± 1.5° (over 360° ), ± 1.0° over 40°
q Pressure
Accuracy
q
Signal Output
PWM, analog, digital (open collector output)
q
Temperature Range
– 40 up to 150°C
q
Supply Voltage
4.5 up to 18 V
0 to 250 bar
q Offset
2.5% full scale
q Span
0.7 up to 2.2% full scale
q Temperature
Range
q Temperature
Accuracy 10°C
q Supply
98
Voltage (Vs)
A & S
– 40°C up to +125°C
5.00 ± 0.5 VDC 99
S & A Sensors
Pressure Sensor – Diesel Particle Filter
Pressure Sensor – Differential Manifold Vacuum
q
Direct measurement of pressure 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
q
q Flexible
Technical Information
Technical Information
q
Pressure Range
q Accurac y
100
measurement of pressure 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
0 up to 125 kPa
q Pressure
1% full scale (10 up to 85°C)
q Accura cy
q
Temperature Range
– 40°C up to +140°C
q
Supply Voltage (Vs)
5.00 ± 0.5 VDC
q
Supply Current at 5 V 10 mA maximum
q
Load Resistance
> 4.7 k Ω
q
Response Time
< 2 ms
Range
q Temperature
–105 up to 40 kPa (gauge) 1% full scale (10 up to 85°C)
Range
– 40°C up to +140°C
q Supply
Voltage (Vs)
q Supply
Current at 5 V 10 mA maximum
q Load
A & S
Resistance
5.00 ± 0.5 VDC
> 4.7 k Ω
101
S & A Sensors
Pressure Sensor – Fuel High Pressure
Pressure Sensor – Manifold Absolute Family
Direct measurement of pressure 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, conn ector, and mounting designs
MAP · T-MAP · BA P · BPS · EVAPO. ..
q q
Pressure Range
q Accurac y
102
pressure signal accuracy over life time q Low cost design and high quality q Customer specific output characteristics by electrical calibration q Modular mechanical concept allows high mounting flexibility
A & S
Technical Infor mation
Technical Information q
q High
0 up to 2200 bar 1% full scale (10 up to 85°C)
q
Temperature Range
– 40°C up to +140°C
q
Supply Voltage (Vs )
5.00 ± 0.5 VDC
q
Supply Current at 5 V 10 mA maximum
q
Load Resistance
> 4.7 k Ω
q
Response Time
< 1 ms
q Adjustable q Pressure
characteristic via e lectronic ca libration
range
q Temperature
q Supply
range
voltage
q Transfer
function
0,1 up to 1 bar (MAP, BAP) 0,2 up to 3 bar (Turbo MAP) – 40 up to 125°C (storage: 135°C ) 5 V ± 0.5 V linear to applied pressure, ratiometric, adjustable
103
S & A Sensors
Pressure Sensor – Truck Application MAP
Truck Applicatio ns
Tank Leakage Control & Air Filter Diagnosis
High pressure signal accuracy over life time q Low cost design and high quality q Customer specific output characteristics by electrical calibration q Modular mechanical concept allows high mounting flexibility
q High
Technical Infor mation
Technical Infor mation
q Adjustable
q Adjustable
q
ch aracteristic via ele ctronic cali bration
pressure signal accuracy over life time q Low cost design and high quality q Customer specific output characteristics by electrical calibration q Modular mechanical concept allows high mounting flexibility
q
Pressure range
up to 5,2 bar absolute
q Pressure
q
Operating temperature
– 40 up to 125°C
q Operating
q
Supply voltage
5 V ± 0.25 V
q Supply
q
Transfer function
linear, ratiometric
q Transfer
q Accuracy
104
Pressure Sensor – Relative
over full -scale 1% full s pan (10 up to 85°C)
characteristic via e lectronic ca libration
range temperature
voltage function
q Accuracy
A & S
over full-sc ale
0 up to 100 mbar diff. – 40 up to 125°C 5 V ± 0.25 V linear, ratiometric 3% full spa n (10 up to 85°C) 105
S & A Sensors
Pressure Switches
Smart NOx Sensor
q Various
Modular »Stand-Alone« NOx Sensor q Standardized electronic interface with CAN-Bus q Independent of catalyst supplier, ECU supplier and engine management system All Ele ctronics including heater control a nd drive rs q integrated in the sensor q Self diagnosis capability regarding shortcut and open wire Calibrated High Accuracy Smart NOx Sensor
q
desig ns avail able Stable over life-time
Technical Infor mation q
Switching points
0.1 up to 100 bar
q
Burst pressure
< 150 bar
q
Switch characteristics Normally open and closed
q Applicat ions
A & S
Oil, air and bra ke pres sure Technical Infor mation q Measuring
principle ZrO 2-based multilayer sensor with integrated heater and 3 oxygen pumps output signal NOx, binary λ , linear λ or O 2-conc.
q Triple
q Supply q Data
106
voltage 12 V or 24 V
link CAN 2.0 or SAE-J-1939
q Operating
gas temperature: 100 up to 800°C
107
S & A Sensors
Temperature Sensor – Coolant/Fuel/Oil
Clip or screw-in design Wide range of applications q High accuracy q Short response time q Long-term stability q Certified quality q High worldwide volume production q Plastic variant available for each type q
q Short
q
q High
Technical Infor mation q
108
Temperature Sensor – Cylinder Head
Oil, water, fuel, temperature measurement – Engine coolant – 40 up to 150°C – Engine oil – 40 up to 150°C – Fuel – 40 up to 140°C
response time accuracy q Stainless steel design q Robustness q Certified quality Technical Infor mation
A & S
q Temperature
Measurement of cylinder head and other solid media
q Different
NTC curves possible
q Cylinder-head
temperature: – 40 up to 230°C
109
S & A Sensors
Temperature Sensor – High Temperature
q Active
110
Temperature Sensor – Intake Air
sensor f or the compara ble pri ce as an passive q High accuracy (ECU will get the data digital, no further corruption of the signal at acquisition) q Price benefit for costumer at ECU-system (no ADC, no precise pull-up) q One design for various application: catalyst monitoring, turbocharger monitoring, DPF, EGR, Selective Catalytic Reduction
q Clip,
Technical Information
q Intake
air temperature measurement
q Intake
air temperature: – 40 up to 150°C
q
Temperature monitoring of exhaust gas temperatures in vehicles
q
Response time: up to 7 s (10 m/s gas flow)
q
Temperature range: – 40° C up to 1100°C
q Accuracy
low te mp. (< 500 °C ): ± 2°C + 0,75% FS O
q Accurac y
high t emp. (> 50 0°C ): ± 7,5° C
q
Supply voltage: 5 V DC (12 V DC, 24 V DC option)
screw design or twist lock design range of applications q High resolution q Short response time q Long-term stability q Certified quality q High worldwide volume production q Wide
A & S
Technical Infor mation
111
S & A Sensors
Temperature Sensor – Intake Air (High EGR)
Measures intake air with high EGR rates Clip or screw design q Very robust q Wide range of applications q Short response time q Certified quality q No chemical and soot impact on N TC
Temperature Sensor – Outside Air
q
q Snap-in
q
q High
design accuracy q Short response time q Long-term stability q Certified quality q High worldwide volume production
A & S
Technical Infor mation Technical Infor mation q
Overpressure
up to 4 bar
q
Response time T63,2 < 7 s (5 m / s air flow)
q Outside
air temperature measurement
q Outside
air temperature: – 40 up to 120°C
q Slash-proof q Different
112
plastic housing
NTC curves possible
113
Fuel Supply – FS
Fuel Supply FS 114
S F
115
Fuel Supply – FS
Modular Fuel Supply Unit
EC Fuel Pump G50D/EC
q Various
q In-tank
cus tomer s pecific designs possible based on modular concept q Flange geometry can be adapted to customer requirements q Integrated tank management q Variants : const ant flow or flow controlled Technical Information q Different
fuel pumps (Ø 38 mm/43 mm) with EC (electronically commutated) or DC (direct current) motor
q Integrated
“lifetime” fuel filter
q Integrated
pressure regulator
( MAgnetic Passive Position Sensor) fuel level sensor
q MAPPS
116
fuel pump with electronically commutated (EC ) motor q Twin channel t urbine pump principle q Emission reduction Technical Information q Performance
data at 12 V:
– Pressure, KPa 400 / 600 – Flow, l/ h typ.
325 / 250
– Current, A typ. 11.3/13.8 q Media
Premium, regular, leaded, unleaded, tropical, Flex Fuel
q Weight
385 g
q Volume
175 cm 3
S F
117
Fuel Supply – FS
Code Description for Names of Fuel Pumps p e m n h t r o u o t r t p i a o o e t f m h u s t d p . m n m p m a u s o t C r c / s p e
C / ] . . f [ f ] . . P [ P # # M
s e r u t h ) r a c e r e a o e u f f t l r o a s i e f a f d c ” f l a n e “ i c a p e n e t o s s ( p s
f
) e n o e l t p n i i h i s t c h i a o c r i p n a m t o e , s f r r e i r p g o f s f a n t ” d p P s o n m “ p e g a u e n m a t t o u p s P s p (
e h t r o r f e s t d e n m a i a # t # s d
p m u p c e i t g a s t a s l
p
r o t o r e
MAPPS ( MA gnetic Passive Position Sensor)
l e u p f t r m o u h p
s
e n i b r u
q Redundant
contacts 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
e n i b r u t e l b u o
q Best
G T D
Technical Information
m m m m m m m m
q Measuring
range
Angle up to 86°
q Operating
current
1 up to 20 mA ~ 2% 1.7° =
q Resolut ion
8 8 3 0 2 3 4 5
q Max.
e h t r o f s a d i n d a e t M s m
118
r r r c t o o o ) i t t n r t a a a s s n t t o e u r e o u t u l p b h c m p m r m e o m u a m C l m s u C u C o o C C E E o r / = C / = C / = C b (
Modular Fuel Level Sensor with MAPPS
e n i l o s a
l a l c i e s G p e P o i r
l e u F x e l
l e s e i D o i
G D L T F B
S F
total error of resistor ± 1%
q Interface
2-wire resistance signal, 50 up to 1000 Ω linear voltage at ADC
q Operating q Dynamic
temperature
strength
– 40°C up to + 125°C 200 m/ s² (0 Hz...1 kHz)
119
Fuel Supply – FS
Fuel Supply Electronics
Modular Function Carrier (MFC)
q Enhanced
q Suitable
fuel pump lifetime in comparison to systems without demand control q Reduced consumption q Noise and emission reduction
for almost all tank designs carbon canister (optional) q Reduction of permeation q Integrated
Technical Infor mation Technical Information q Integrated
in the flange of the fuel supply unit or stand-alone
q Enables
an EC ( electronically commutated) or DC ( direct current) fuel pump to provide only the amount of fuel to the engine which is currently demanded
q Processing q Integrated
120
q Operating
ventilation
q Refueling
ventilation (optional)
q Roll
over function
q Retaining
(optional)
vapor with integrated carbon canister
S F
of fuel level sensor signals (optional)
theft protection (optional)
121
Catalytic Converters – CC
Catalytic Converters CC
C C
122
123
Catalytic Converters – CC
METALIT® (3-Way-Cat)
NO X-Adsorber
Leading metallic substrate technology
NO X-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 µm
q Structured foils for enhanced efficiency are possible q Cell densities 50 up to 1600 cpsi
Technical Information q Capacity
and regeneration are important for overall efficiency and fuel economy
q High
cell densities help to improve mass transfer and therefore conversion efficiency
q Enhanced
functionality due to included NO X Sensor
q Additiona l
storag e volum e afte r the sensor increases safety margin
124
C C
125
Catalytic Converters – CC
Pre Turbo METALIT TM
Compact Cat ®
Excellent Cold Start Performance
Compact design for close coupled applications with optimized heat management
Technical Infor mation Technical Infor mation
q
Use of higher exhaust gas temperature
q
Increases HC/CO efficiency (turbulent flow)
q
Reduces the needed Diesel Oxidation Catalyst volume
q Mounted
q
Significant system cost reduction possible (Preturbo Catalyst + Diesel Oxidation Catalyst)
q High
q Compact
design for close c oupled applications especially for Diesel applications directly to the turbocharger for fast light-OFF efficiency due to optimized heat management
q Potential
for cost savings by volume reduction
C C
126
127
Catalytic Converters – CC
PM-METALIT ®
SCRi ®-System
Urea
Oxicat
LS- & PE-Design TM
PMMETALIT ®
PM-METALIT ®
SCR-Cat
LS-Design ®
Partial – flow deep bed filter for ultrafine particulate matter
Catalyst system with integrated particle reduction and turbulent substrates
Technical Infor mation
Technical Infor mation
q
Particulates are deviated in the shovel and deposed in the fleece layer
q
In conjunction with NO 2 from the oxidation catalyst continuous particle reduction
q
Side-flow system guarantees discruption-free engine operation through deep-bed filtration
q
EU 4/5 without urea
q Future
filter strategies have to be adapted to changing particulate sizes
q Continuously
working particle system without
regeneration q Above-a verage
eliminat ion in s mallest particle s
q High
performance reduction catalyst turbulence generating LS/PE-Design with optimized coating allows volume reduction
C C
128
129
Catalytic Converters – CC
LS-Design ®
PE-Design TM
Turbulent Cataly st
Turbulent Cataly st
Technical Infor mation
Technical Infor mation
Longitudinal Structure Design
Perforated Metal Foil Design
q
Reduction of material/weight
q Lower
backpressure
q
Improvement of cold start performance
q Faster
light off
q
Increased mass transfer
q Improved
q
Catalyst efficiency
turbulent mass transfer
C C
130
131
