04/21/2009 The latest injection technology and Continental's engine and transmission controls for cost-sensitive markets in Asia, Eastern Europe and South America.

Shanghai, April 21, 2009. The emerging vehicle markets in Asia, Eastern Europe and South America are developing rapidly. There is also an increasing demand in these markets for the latest technology in order to comply with more stringent emissions regulations and to reduce fuel consumption and thus vehicle CO2 emissions. For these cost-sensitive markets where most vehicle models sell for considerably less than €10,000, the Powertrain Division within Continental AG, the international automotive supplier, can provide a complete portfolio of low cost internal combustion engine components. The central feature is the new "Easy-U" engine management system, which comes with a fully validated set of actuators, sensors plus special fuel pumps, and the new transmission control system based on the "EAST Platform" for automatic and double-clutch transmissions.

The challenge was to get engineers in each region to develop and produce high-tech products which meet local low-cost-market requirements. This enables Continental to satisfy the varying requirements of vehicle manufacturers and markets quickly and extremely flexibly. In addition to its automotive development know-how, Continental is also relying on synergy effects from its engineering experience in the motorcycle and non-automotive fields.

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The latest injection technology and Continental's engine and transmission controls for cost-insentive markets

Emissions regulations act as technology drivers

Purchasers of cars in different world markets demand widely varying standards of comfort, performance and safety. However, as regards the legal requirements set out in their emissions regulations, the gap between western industrialized countries and the emerging markets, i.e. predominantly India, China, Russia and Brazil, has shrunk significantly. Whereas, in the very recent past, China lagged six years behind European regulations, the Euro 4 standard now applies in their megacities and in ten major Indian cities as well. These emission levels can only be achieved through state-of-the-art engine management and injection systems. In the "affordable cars" segment, some 90 percent of all registered passenger cars are fitted with gasoline engines for cost reasons. More over, car makers in China and other developing countries are now being set on exporting towards industrialized countries, meaning that systems fit on their cars must comply with Western regulatives.

A complete portfolio for the internal combustion engine

When developing inexpensive engine management systems, injectors, fuel supply systems and sensors, Continental's Powertrain Division can draw not only on its mature expertise gained in classical automotive markets but can also exploit the synergy effects from its Synerject subsidiary. This joint venture company, established over ten years ago together with the Orbital Engine Company, specializes in engine management systems for motorcycles, boats and other leisure sports vehicles. Consequently, development work has incorporated much of the technology used for the small one, two and four-cylinder engines in this less expensive segment; this technology transfer, especially from motorcycles to cars, will accelerate in the next few years.

Transmission Control Unit "East TCU"

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In addition to the innovative 32 bit "Easy-U" engine management system, which can be flexibly adapted to the relevant vehicle architecture, the total package on offer includes injectors, air pressure and temperature sensors, electronic throttle bodies, stepper motors, crankshaft, camshaft and knock sensors. "Easy-U" was developed at the company's Chinese sites, with support from Europe. The start of serial production of "EASY-U" is scheduled this year in Changchun in China, and most of the sensors and actuators used in this system are also manufactured in China.

2009 will also see the start of series production in Changchun of the newly-developed transmission control unit, to be marketed under the name of "EAST TCU". The controller is a rapid-acting 32 bit controller in a compact housing and has a wide variety of possible uses. It is engineered in China with support from Europe, with the target to address various applications in the emerging markets. The EAST TCU is designed as an electronic platform that can monitor and control continuously variable transmissions (CVT), wet double clutch transmissions (DCT), hydraulic AMT and traditional automatic transmissions. An evolution of the EAST TCU that will address electromechanical actuation is being developed, thus allowing to cover the complete range of automatic transmissions. Shortened time to market and reduced engineering efforts for application, together with the cost competitiveness of the EAST TCU, will be an enabler for the Automatic Transmission market in China and in other developing automotive market.

Engine Control Unit "Easy-U"

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Hybrid and electric drive technology is also gaining in importance in emerging markets. Continental, as a worldwide supplier of the complete range of hybrid technology from lithium-ion energy storage units to power electronics, is playing a significant role in promoting this technology. Several series production contracts for mild hybrid drives are currently running in China. Because the markets for "affordable cars" are so price-sensitive, the challenge here as well is to implement high-tech solutions more simply and less expensively but, at the same time, to pro-vide functionality comparable to that installed in vehicles for Western Europe or North America.  A key role will be played by cars with purely electric drive systems, mainly intended for use as city runabouts in densely populated areas and for which there is already an increasing demand.

Continental has been producing hybrid components since 2003. In 2008, Continental started series production of lithium-ion batteries to be used in hybrid drive cars. It will be installed as standard in the new Mercedes S400 BlueHYBRID, available from the middle of 2009. Continental has already begun production of its EPF1 series of power electronics and is now developing the second generation power electronics EPF2 with it established customers for use in hybrid and electric vehicles. Through innovative design and packaging Continental was able to reduce the volume of the unit by significantly, while at the same time increasing its performance. The EPF2 is designed for battery voltages from 85 to 400 volts and can drive motors up to 75 kW. Continental is planning to manufacture hybrid components in its Tianjin facility.

By 2015 one car in five worldwide will be an "affordable car"

The automotive trade is expecting strong growth in the low-cost vehicle market in the coming decade, particularly in the emerging markets of Asia. Studies have concluded that the production of "affordable cars", i.e. cars which cost the end user less than €10,000, will increase, mainly in India and China, by up to 70% from today until 2015. Similar growth rates are also forecast for Eastern Europe and South America. By the middle of the next decade, one in every five cars produced throughout the world will be in this category. But, there will be a wide range of prices within this category; while studies have shown that the average price in Europe will be in the range of €8.000 - €11.000, the price in India will be around €2,400.