Reducing Consumption Using the Modular Principle

CO2 reduction: intelligent technologies for environmentally-friendly driving

Frankfurt, September 10, 2007 -- Continental Automotive Systems is using ground-breaking technologies to significantly reduce the levels of CO2 emitted by vehicles: Hybrid drives can reduce fuel consumption and thus exhaust gas emissions by up to 25 per cent. The Automotive Systems division of the international automotive industry supplier, Continental, has therefore developed hybrid drive components and complete systems with the aim of launching these environmentally-friendly technologies quickly and at a competitive price. Hybrid drives reduce consumption further still when used in combination with the innovative double-clutch transmission, for which Continental Automotive Systems develops and produces the control units. Continental Automotive Systems' experience as a brake manufacturer is useful for the development of regenerative brake systems which play a key role in saving energy in hybrid vehicles, and also for the manufacture of weight-optimized brake components that reduce consumption. Tire pressure is an very important factor when it comes to saving fuel. Continental Automotive Systems has developed a new technology - the intelligent Tire Pressure Monitoring System, which can go soon into series production.

Scaleable hybrid drive systems from a single source
Continental Automotive Systems is working with several automotive manufacturers to push forward series production projects for hybrid vehicles. These projects include start-stop systems to switch off the engine automatically at red lights, mild hybrid drives which supply additional torque to combustion engines during acceleration and use regenerative braking functions to charge the energy storage unit, and full hybrid drives with the option of fully-electric driving. The flexible modular concept includes the energy storage unit (high performance battery), a voltage transformer for the 14-volt onboard power supply, an electric motor and the inverter for different power outputs. The components compose scaleable hybrid systems with additional electric outputs of up to more than 150kW (204 bhp), which reduce consumption but also make driving much more enjoyable.

The modular components are also suitable for electric drives in plugin hybrid applications and fully electric vehicles or the fuel cell vehicles of the future. Their system architectures are also compatible with Continental Automotive Systems brake systems including the Simulator Brake Actuation (brake-by-wire pedal).

The inverter is a key element of the hybrid drive system. Depending on the amperage and voltage, the inverter is the determining factor for the overall efficiency of the hybrid drive, because it ensures that as much kinetic energy as possible is recovered and fed back to the energy storage unit during the overrun phases. The more often and the quicker the storage unit is charged, the more frequently the electric engine can relieve the combustion engine.

The ambitious objective of the near future is to achieve “electronics in five liters construction volume�? - to reduce the space required for the power electronics. Its components are to be integrated into a housing the same size as the alternator (redundant in hybrid vehicles). This would significantly reduce production costs.

Continental Automotive Systems is also developing an electric axle drive, which would simplify integration of the hybrid system and help keep costs to a minimum.

Power generation and dynamic brake power distribution
When braking a hybrid vehicle, the electric motor works as a generator to charge the battery. The Continental Automotive Systems regenerative brake system (RBS) is designed largely on the basic concept and modules of traditional brakes. The system is supplemented with a pedal feel simulator and pedal angle sensor. The simulator gives the driver the ideal pedal feel, because the deceleration effect is mostly achieved by the braking torque of the hybrid system rather than the disk brake. The regenerative brake system also offers all the usual brake, safety and stability functions.

Continental Automotive Systems developed the electric-hydraulic combi brake (EHC), an innovative brake system for use in hybrid vehicles. The EHC combines hydraulic front axle wheel brakes with fully-electric wheel brakes on the rear axle. The EHC allows lower residual friction coefficients than traditional brake systems and enables effective recuperation, thus saving energy.

Efficient energy management due to double-clutch transmissions
The more energy is recuperated during braking, and the lower the loss of additional torque from the electric motor when it is transferred to the drive wheels during acceleration, the higher the efficiency of a hybrid drive. With the combination of hybrid drive and double-clutch transmission (DCT), Continental Automotive Systems can identify previously unused potential in the drive train. Efficient gear changes with DCT prevent interruptions to the power flow from the crankshaft to the drive wheels, and performance is not diminished by any slip generated in the torque converter. There are not only advantages during acceleration; the double-clutch transmission is also beneficial when allowing the vehicle to run on or when braking. Depending on the charge state of the battery, a hybrid controller creates a balance between the drag torque of the electric motor and the braking power of the wheel brakes. The frictional connection is not interrupted which means that the energy storage unit can be charged optimally. In total, the potential for saving fuel is between five and ten per cent, depending on the class of vehicle. "Combinations with DCT indicate that our company is a leading player when it comes to promoting environmentally-friendly hybrid technologies�?, said Dr. Karl-Thomas Neumann, chairman of the board of directors of Continental Automotive Systems and member of the management board of Continental AG.

Intelligent tires: precise information about tire pressures whenever you need it
Over two billion liters of fuel are needlessly emitted into the atmosphere in Europe each year because nearly one in two drivers takes to the roads with insufficient tire pressure. This increases fuel consumption, but aside from that, the potential tire damage poses a huge safety risk. With the intelligent tire pressure monitoring system, Continental has developed a new generation of direct measurement and monitoring, which will go into series production at the end of 2009.

The sensor module to record tire pressure and temperature is no longer located on the wheel valve; it is stuck to the inside of the tire. This protects the nine-gram sensor more effectively. If the sensor is secured to the tire by the tire manufacturer, data about the type (summer or winter tires) and date of manufacture, recommended pressures, speed index and maximum load can be stored in the module. The sensor sends this data and the current tire pressures to the vehicle, enabling more effective control by the brake system and ESC. Various load conditions can also be detected by the optional wheel load sensor.

Weight saving during braking: development work in detail
Each gram of vehicle weight is significant for reducing fuel consumption. Continental Automotive Systems has therefore developed weight-optimized brakes. Thanks to a special manufacturing technique, new brake pad backplates are thicker in highly stressed areas. This allows a saving of around 300 grams per brake without additional costs or losses in performance.

With a modular system Continental Automotive Systems can respond flexibly to the customers` demands for lighter boosters. It is possible to reduce weight by up to 40 per cent in the brake actuation mechanism, for example by using aluminum or tie rods.

The Continental Corporation is a leading automotive supplier of brake systems, chassis components, vehicle electronics, tires and technical elastomers. In 2006 the corporation realized sales of EUR14.9 billion. At present it has a worldwide workforce of around 89,000.

As a worldwide leading technology and systems partner to the automotive industry, the Automotive Systems Division of Continental AG integrates extensive know-how and uncompromising quality in the fields of active and passive driving safety, embedded telematics and hands-free communication systems, powertrain and comfort. In 2006 the Division achieved sales of approx. Euro 6 billion with a workforce of more than 30,000. Continental Automotive Systems develops and produces electronic and hydraulic brake, stability and chassis control systems, electronic air suspension systems, sensors, engine management and transmission control systems, hybrid drives, cooling fan modules, body and security electronics and also is the industry leader of embedded telematics and communication systems in vehicles.

Source: Continental

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