Product Booklet en

Powertrain Products 2 3
If everyone drives a car, Content

can our air still be clean?
Powertrain Focus Areas
Combustion Drivetrain Efficiency
Systems Gasoline and Performance
Combustion
Systems Diesel Electrification
Exhaust
Aftertreatment
10 System Overviews
10 Gasoline Direct Injection System
12 Gasoline Port Fuel Injection System – Naturally
There are two decisive factors influencing the devel- Aspirated
opment of drive technologies: active climate protec- 14 Diesel Injection and Aftertreatment System
tion, particularly the reduction of CO2 and exhaust
emissions. And secondly, the increasing need for 16 ES – Engine Systems
individual mobility, which results in various require- 18 EMS3 Engine Management System Platform
ments on vehicles and drive systems. 19 ECU Gasoline Port Fuel Injection
20 ECU Gasoline Port Fuel Injection Ready-to-use EasyU
Under the guiding concept of “Clean Power,” the 21 ECU Gasoline Solenoid Direct Injection
Powertrain Division is developing innovative solu- 22 ECU Gasoline SDI Ready-to-use EasyU
tions both for gasoline and diesel engines and for 23 ECU Bi-Fuel Ready-to-use EasyU
electrical drive sys- 24 ECU Gasoline SDI and TCU
tems. These not only 0.005 mm If you
were 25 ECU Diesel Piezo Common Rail
make driving more en- human hair one hundredtotimes,
split a
you 26 ECU Diesel PCR Ready-to-use
vironmentally friendly would have the tolerance of the 27 ECU Diesel PCR Ready-to-use 12 V / 24 V
and affordable, but nozzle needle in our piezo injector. 28 ECU Diesel Platform for Commercial Vehicles
This ultra-high precision enables
also enhance comfort better performance with lower fuel 29 ECU Diesel Heavy Duty Engines
and the fun to drive. consumption. 30 ECU Aftertreatment Control ACM2
Content
31 ES – Engine Systems 61 SYN – Synerject

31 Glow Plug Control with SCR Heater 61 Electronic Oil Pump Single or Multi Port
32 Selective Catalytic Reduction Dosing Control Unit 62 Customized Fuel Delivery Module
33 Connected Energy Manager 63 Customized Fuel Rail Assembly
34 Gasoline High Pressure Pump GHP2.5 64 Ignition Coil
35 Diesel High Pressure Pump DHP1.1 65 Oxygen Sensor
36 Diesel High Pressure Pump DHP2
37 Diesel High Pressure Pump DHP3 66 HEV – Hybrid Electric Vehicle
38 Gasoline DI XL3.1 Solenoid Injector
68 12 V Power Net System
39 Gasoline DI XL5 Solenoid Injector
69 12 V Dual Battery Manager
40 Gasoline Deka 7/9 Port Fuel Injector
70 48 V Belt-driven Starter Generator
41 Gasoline Deka 10 Port Fuel Injector
71 48 V DC/DC Converter
42 Diesel Piezo Common Rail Injector PCRs2
72 48 V Battery Management System
43 Diesel Piezo Common Rail Injector PCRs5
73 HV Axle Drive with integrated Inverter
44 Diesel Fuel Rail
74 HV Power Electronics (Inverter with DC/DC Converter)
45 Gasoline Fuel Rail Assembly
75 HV Inverter
46 LPG Liquified Petroleum Gas Injector
76 HV DC/DC Converter
47 Air Cooled SCR Injector

48 Liquid Cooled SCR Injector
78 TR – Transmission
49 Diesel Dosing Injector
50 Gasoline Turbocharger – Steel Turbine Housing 80 Control Unit for Double Clutch Transmission
51 Gasoline Turbocharger – Aluminum Turbine Housing 81 Control Unit for Double Clutch Transmission
52 SYN – Synerject 82 Control Unit for Double Clutch Transmission
53 M3A Air Module Engine Control Unit 83 Control Unit for Double Clutch Transmission
54 M3B Air Module Engine Control Unit 84 Control Unit for Double Clutch Transmission
55 M3C Engine Control Unit 85 Control Unit for Double Clutch Transmission
56 M3D Ride by Wire Engine Control Unit 86 Control Unit for Double Clutch Transmission
57 Customized Engine Control Unit 87 Control Unit for Double Clutch Transmission
58 Mechanical Throttle Body Module 88 Control Unit for Double Clutch Transmission
59 Customized Electronic Throttle Body 89 Control Unit for Double Clutch Transmission
60 Strata Air Injector 90 Control Unit for Double Clutch Transmission
Content
91 TR – Transmission 120 S & A – Sensors & Actuators

91 Control Unit for Stepped Automatic Transmission 20 Digital Linear Actuator – Standard Size – Gen I
1
92 Control Unit for Stepped Automatic Transmission 121 Digital Linear Actuator – Standard Size – Gen II
93 Control Unit for Stepped Automatic Transmission 122 Digital Linear Actuator – Standard Size – Gen V
94 Control Unit for Stepped Automatic Transmission 123 Electrical Compressor Bypass Valve
95 Control Unit for Stepped Automatic Transmission 124 Electrical Exhaust Gas Recirculation Valve
96 Control Unit for Stepped Automatic Transmission 125 Electrical Wastegate Actuator
97 Control Unit for Continuously Automatic Transmission 126 Electronic Throttle Control ETC 12
98 Control Unit for Continuously Automatic Transmission 127 Exhaust Control Valve – High Pressure
99 Control Unit for Commercial Vehicle 128 Exhaust Control Valve – Linear
100 Control Unit for Commercial Vehicle 129 Exhaust Control Valve – Low Pressure
101 Control Unit for Double Clutch Transmission (CV) 130 Latching Valve
102 EAST Transmission Control Unit Platform 131 Linear Purge Valve
103 Control Unit for Limited Slip Coupling 132 Natural Vacuum Leak Detection (NVLD III)
104 Control Unit for Transfer Case 133 Pump – Electrical Water Pump
105 Multi Position Linear Actuator 134 Pump – Twin Drive Pump
106 Direct Shift Module 135 Turbo Purge Valve
107 Sensorcluster for Automatic Transmission Applications 136 Variable Turbine Geometry Actuator
137 Door Handle Sensor
108 S & A – Sensors & Actuators 138 Easy Trunk Access Sensor
139 Electrostatic Particulate Matter Sensor
10 Active Purge
1 140 Fluid Sensor – Biodiesel
111 Air Control Valve – Economy Line S11.1 141 Fluid Sensor – Flex Fuel Ethanol
112 Air Control Valve – Economy Line S11.2 142 Fluid Sensor – Oil Level Passive Electrothermic
113 Air Control Valve – Performance Line S6 143 Fluid Sensor – Oil Level Switch
114 Air Control Valve – Performance Line S6 HT 144 Fluid Sensor – Oil Level Ultrasonic
115 Air Control Valve – Perform. Line S8.6 (MD / HD Truck)
145 Fluid Sensor – Urea Concentration and Level
116 Air Control Valve – Smart ACV
146 In Cylinder Pressure Sensor
117 Brushless DC Drives – High Efficiency
147 Knock Sensor – M6
118 Canister Purge Solenoid CPS6
148 Knock Sensor – Wide Band
119 Digital Linear Actuator – Compact Size – Gen VII
149 Mass Airflow Sensor – FMT MAF SENT
Content
150 S & A – Sensors & Actuators 180 FEM – Fuel & Exhaust Management
50 Mass Airflow Sensor – FMT MAF + HPT SENT
1 80 Fuel Level Sensor with an Open Contact System
1
151 Mass Airflow Sensor – MT 181 Electric Fuel Pump – EC
152 Near Field Communication External Reader 182 Electric Fuel Pump – DC
153 Position Sensor – Linear Contactless 183 Fuel Delivery Controller
154 Position Sensor – Linear Contactless 184 Tank Domain Controller
155 Position Sensor – Rotary Contactless 185 Flat Channel METALIT® (Standard Structure)
156 Pressure Sensor – Brake Booster Absolute 186 CS-Design (Crossversal Structure)
157 Pressure Sensor – Brake Booster Gauge 187 LS-Design® (Longitudinal Structure)
158 Pressure Sensor – Filter Control Gauge 188 PE-Design® (Perforated Structure)
159 Pressure Sensor – High Pressure Diesel 189 LS-Design® and PE-Design®
160 Pressure Sensor – High Pressure Gasoline 190 TS-Design® (Transversal Structure)
161 Pressure Sensor – Manifold Absolute 191 PM-METALIT® (Particulate Matter Filter)
162 Pressure Sensor – Manifold Absolute and Temperature 192 MX-Design® (Mixing Structure)
163 Pressure Sensor Manifold Gauge 193 Mantle-less Metallic Substrate
164 Pressure Sensor – Particle Filter Differential (2 Ports) 194 Exhaust Gas Recirculation Filter
165 Pressure Sensor – Particle Filter Gauge (Single Port) 195 EMICAT® Electrically Heated Catalyst
166 Pressure Sensor – Secondary Air Absolute 196 Controller for Electrically Heated Catalyst (EMICAT®)
167 Smart NOX Sensor 197 Modular Diesel Engine System
168 Smart Position Sensor – Cover 198 Closed-Coupled Exhaust Aftertreatment System
169 Temperature Sensor – Coolant / Fuel / Oil Gasoline
170 Temperature Sensor – EGR 199 Closed-Coupled Exhaust Aftertreatment System Diesel
171 Temperature Sensor – High Multiple 200 Compact SCR EHC System
172 Temperature Sensor – High Single 201 Air-assisted Urea Dosing Unit UDA
202 SCR Catalyst
174 FEM – Fuel & Exhaust Management
76 Fuel Delivery Module for Standard Applications
1
177 Fuel Delivery Module for High-End Applications
178 Fuel Delivery Module for Entry Level Vehicles
179 Fuel Level Sensor with a Sealed Contact System
System Overviews 10 11
Gasoline Direct
Injection System
1 2 3 4 5 6 14 15
7
8
9 10 11 12 13 16 17 18 19 20 21 22
1 Engine Control Unit 13 Fuel Rail

2 Mass Airflow Sensor 14 Gasoline Direct Injection Solenoid Injector
3 Turbocharger 15 3-Way Catalyst
4 Manifold Absolute Pressure Sensor 16 Manifold Absolute Pressure Sensor with integrated
5 Electronic Throttle Control Temperature Sensor
6 High Pressure Exhaust Control Valve 17 Oil Level Sensor
7 Canister Purge Solenoid 18 Active Crankshaft Position Sensor
8 Flex Fuel Ethanol Sensor (also with Direction Detection)
9 Natural Vacuum Leak Detection (NVLD II) 19 Knock Sensor
10 Fuel Delivery Module 20 Coolant (Water) Temperature Sensor
11 Gasoline High Pressure Pump 21 Variable Lift Control Actuator and Sensor
12 Fuel High Pressure Sensor 22 Active Camshaft Position Sensor
Gasoline Port Fuel Injection

System – Naturally Aspirated
1 2 3 4 5
6 7 8 9 10 11 12 13 14 15
1 Canister Purge Solenoid 9 Manifold Absolute Pressure Sensor

2 Flex Fuel Ethanol Sensor with integrated Temperature Sensor
3 Electronic Throttle Control 10 Gasoline Port Fuel Injector
4 Fuel Rail 11 Active Crankshaft Position Sensor (also with
5 Pressure Regulator Direction Detection)
6 Natural Vacuum Leak Detection (NVLD II) 12 Knock Sensor
7 Fuel Delivery Module 13 Coolant (Water) Temperature Sensor
8 Engine Control Unit 14 Active Camshaft Position Sensor
15 3-Way Catalyst
Diesel Injection and

Aftertreatment System
1 2 3 4 5 6 7 8 9 10 11 12 20 21 22 21 23 24 25 26 27 23 28
SCR +
DOC DPF
21 21 29 30
13 Fuel Delivery Module
17 14 Biodiesel Sensor
15 Diesel High Pressure Pump
18 16 Fuel Rail with High Pressure Sensor and Pressure
13 14 15 16 19 Decay Valve
17 Coolant (Water) or Cylinder Head Temperature Sensor
1 Engine Control Unit 18 Crankshaft Position Sensor
2 Mass Airflow Sensor 19 Oil Level Sensor
3 Low Pressure Exhaust Control Valve 20 Variable Turbine Geometry Actuator
4 Air Control Valve 21 High Temperature Sensor
5 High Pressure Exhaust Control Valve 22 Diesel Dosing Unit
6 Exhaust Bypass Valve 23 Smart NOX Sensor
7 Manifold Absolute Pressure Sensor with integrated 24 Deka SCR Injector
Temperature Sensor 25 Particle Filter Differential Pressure Sensor
8 Camshaft Position Sensor 26 Urea Concentration and Level Sensor
9 EGR Pressure Sensor 27 Tank Integrated Extraction and Pump Unit
10 Swirl Control Actuator 28 Distributed Function Control Unit for SCR
11 Diesel Piezo Common Rail Injector 2 9 Particulate Matter Sensor
12 In-Cylinder Pressure Sensor 30 Exhaust Throttle Valve
ES – Engine Systems 16 17
Engine Systems
EMS3 Engine Management ECU Gasoline

System Platform Port Fuel Injection
ES
PowerSAR®
Electronic and SW EMS platform for powertrain: gasoline, Scalable, modular, validated electronic and SW platform
diesel, commercial vehicle. Scalable for worldwide markets. with standardized chipset for various PFI engines.
› For Euro 6+ gasoline / diesel drivetrain and › Gasoline port fuel injection system
Benefits
Benefits
electrical drive: PFI, SDI, PCR, flex fuel, CNG
› Chassis mounted
› Supports various engine sensors and actuators
› E100 capability
› Improved power consumption and higher function
integration › Supports Euro 6
› Up to 6 cores and 16 MB flash size › Core: Monaco /Andorra, 80 MHz
Technical Information
› Interfaces: CAN-FD, LIN, FlexRay, SENT, PSI5, Ethernet › Flash size: 1.5 MB or 2 MB
› Generic Timer Module V3.1 (GTM) › Interfaces: CAN, CAN-WakeUP, LIN
› Injector drivers: 2 piezo up to 8 piezo, solenoid › Injector drivers: 4 PFI, CNG, E100
› Driver outputs: 16 up to 60, flexible high-/ low-side › Driver outputs: 34
› Connector pins: Up to 196 (300 in combination)
› Tightness: IP6K9K
› ISO 26262, PowerSAR®: AUTOSAR 4.2,
multicore freely distributable › Connector pins: 115
ECU Gasoline Port Fuel ECU Gasoline

Injection Ready-to-use EasyU Solenoid Direct Injection
ES
Scalable, modular electronics and SW for various engines. Scalable, modular, validated electronic and SW platform
Configurable off-the-shelf engine control unit. with standardized chipset for various SDI engines.
› Mature validated HW and SW platform for various › ECU with multiple options: variable valve lift control,
Benefits
Benefits
vehicle configurations: EOBD, VVT, EGR, turbo, VIM, lambda control LIN / BIN, turbocharger
PORT and start /stop
› Encryption for hardware protection (SHE )
› Fast time to market › Supports Euro 6
› Supports Euro 6
› Core: Tricore and Power PC architecture
› Core: Monaco /Andorra
› Flash size: 2.5 MB up to 16 MB

› Flash size: 1 MB /1.5 MB / 2 MB › Interfaces: CAN-FD, LIN, FlexRay, SENT, PSI5,
› Interfaces: CAN, LIN, K-Line Ethernet
› Ignition driver: Internal IGBT or external › Injector drivers: 3 up to 6 SDI / PFI
› Driver outputs: High-/ low-side, up to 6 H-bridges
› Injector drivers: 4 PFI
› Tightness: IP6K9K, IP67 › Tightness: IP6K9K
› Connector pins: 96 or 128 › Connector pins: 336
› Housing temp. range: – 40°C up to + 105°C › ISO26262, AUTOSAR 4.2

ECU Gasoline SDI ECU Bi-Fuel

Ready-to-use EasyU Ready-to-use EasyU
ES
Scalable, modular electronics and SW for various engines. Scalable, modular ECU for bi-fuel applications.
Configurable off-the-shelf engine control unit. One electronic for gasoline PFI, CNG, LPG.
› Mature validated HW, SW and calibration platform › Mature validated HW and SW platform
Benefits
Benefits
› Standardized electronic chipset › Standardized, validated electronic chipset
› HW, SW basic configuration ready for production › Engine management control unit or interface box
› Fast time to market for CNG, LPG
› Supports Euro 6 › Chassis mounted
› Supports up to Euro 5
› Core: Andorra, 120 MHz
› Core: Monaco, 80 MHz

› Flash size: 2 MB Technical Information
› Interfaces: 2 CAN, LIN › Flash size: 1.5 MB
› Injector drivers: 4 SDI › Interfaces: CAN, LIN, K-Line
› Driver outputs: 26, 2 H-bridges › Injector drivers: 4 PFI + 4 CNG / LPG P&H injector
› Tightness: IP6K9K › Driver outputs: 37 + 1 H-bridge + 4 IGBTs
› Connector pins: 160 › Tightness: IP6K9K
› Housing temp. range: – 40°C up to + 95°C › Connector pins: 115
ECU Gasoline SDI and TCU ECU Diesel

Piezo Common Rail
ES
Scalable, modular, validated electronic and SW platform Scalable, modular, validated electronic and SW platform
with standardized chipset for various engines. with standardized chipset for various engines.
› Combined control unit for gasoline solenoid › Controls direct- and servo-driven piezo injectors
Benefits
Benefits
direct injection and transmission control › Control of high pressure pump
› CVT or 6 speed automatic transmission control › Control of SCR subsystem (sensors and actuators)
› Chassis mounted › Supports Euro 6
› Supports Euro 6
› Core: Tricore and Power PC multicore
› Core: EMS: TC1782 133 MHz, architecture
TMS: TC1724 80 MHz › Flash size: 2.5 MB up to 8 MB

› Flash size: EMS: 2.5 MB, TMS: 1.5 MB › Interfaces: CAN, LIN, FlexRay, SENT, PSI5
› Interfaces: 2 CAN, LIN, FlexRay › Injector drivers: 3 piezo up to 8 piezo
› Injector drivers: 4 SDI › Driver outputs: High-/ low-side, up to 5 H-bridges
› Driver outputs: 49 + 4 H-bridges › Housing: Aluminum or magnesium
› Tightness: IP6K9K › Connector pins: Up to 196 (300 in combination)
› Connector pins: 196 › ISO26262, AUTOSAR 4.2
ECU Diesel PCR ECU Diesel PCR

Ready-to-use Ready-to-use 12 V / 24 V
ES
Scalable, modular electronics and SW for various engines. Scalable, modular electronics and SW for various engines.
Off-the-shelf ECU for passenger and light duty vehicles. Off-the-shelf ECU for light duty vehicle engines.
› Mature validated HW, SW and calibration platform › Mature validated HW and SW platform
Benefits
Benefits
› Standardized electronic chipset › Standardized electronic chipset
› Fast time to market › Fast time to market
› Chassis mounted › Chassis mounted
› Supports Euro 6 with external SCR › Supports Euro IV and V
› Core: Monaco / Andorra › Core: TC1767

› Flash size: Up to 4 MB › Flash size: 2 MB

› Interfaces: CAN, LIN, K-Line › Interfaces: 2 CAN, K-Line
› Injector drivers: Up to 4 PCR, one bank › Injector drivers: Up to 4 PCR, one bank
› Driver outputs: 28 + 3 H-bridges › Driver outputs: 32 + 1 H-bridge
› Tightness: IP6K9K › Tightness: IP6K9K
› Connector pins: 115 › Connector pins: 128
ECU Diesel Platform ECU Diesel

for Commercial Vehicles Heavy Duty Engines
ES
Off-the-shelf ECU and SW for medium and heavy duty Scalable, modular, validated electronic platform for diesel
vehicle engines for diesel solenoid and CNG. solenoid medium and heavy duty engines.
› Standardized, scalable and modular electronics › Diesel engine management for amplified common
Benefits
Benefits
and SW rail and pump-line-nozzle and other solenoid
injection systems
› On-engine mounted with dampers
› 12 / 24 V universal voltage › On engine mounted with damping elements
› Supports CNG injection systems › Fulfills current emission requirements

(EPA 2010 +, Euro VI+, combined with SCR)
› Supports Euro IV and Euro V
› Core: TC1796
› Core: Monaco /Andorra
› Flash size: 2 MB
› Flash size: 1.5 MB up to 4 MB
› Interfaces: 3 CAN
› Interfaces: 2 CAN
› Injector drivers: 12
› Injector drivers: Up to 6 cylinders, two banks
› Driver outputs: 26 + 1 H-bridge › Driver outputs: 21 + 1 H-bridge
› Tightness: IP6K9K › Tightness: IP69K, IP67

ECU Aftertreatment Control Glow Plug Control

ACM2 with SCR Heater
ES
Controller for exhaust aftertreatment systems (SCR, DPF). Single electronic controller for glow plug and SCR heater.
› 12 V/ 24 V supply › Glow plug PWM control with electrical diagnosis

Benefits
Benefits
› Supports CAN based sensors (e.g. NOX , urea quality) › SCR on /off control with electrical diagnosis
› Chassis mounted (under hood) › Control of the SCR heater power relay
› Redundancy for protection of glow plug outputs
› Core: Andorra
› Flash size: 4 MB › Core: Bolero, 32 MHz
› Interfaces: 3 CAN › Flash size: 256 KBytes
› Injector drivers: 3 urea or HC dosing › Interfaces: CAN, 2 dedicated PWM lines
› Driver outputs: 4 high-side + 19 low-side › Driver outputs: 8 high-side drivers
› Tightness: IP5K6K › Housing sealed: IPX9K
Selective Catalytic Reduction Connected Energy Manager

Dosing Control Unit
ES
Standardized, validated electronic and SW platform for Central processing unit for eco-driving connected energy
NOX aftertreatment control of passenger vehicles. management functions. For passenger vehicles (12 V).
› Proven mechanical and electronic concepts › Calculates and distributes torque request to various
Benefits
Benefits
(driver, ASICs etc. ) powertrain control units (engine, e-motor, battery,
transmission)
› 2 connector approach enables optimized wiring
harness › Enables CO2 savings via predictive driving algorithms
› Direct connection to ECU and pump module › Communications gateway
› Reduces number of ECU variants
› Core: Bolero
› Flash size: 1 MB › Core: Tricore multicore architecture

› Interfaces: CAN, SENT, PWM › Flash size: Up to 16 MB
› Injector drivers: High-/ low-side › Interfaces: CAN, LIN, FlexRay, SENT, Ethernet
› Heater driver: 2 › Drivers: High-/ low-side, H-bridges
› Pump driver: BLDC pump › Housing: Plastic, Connectors with 2 chambers
› Housing: Plastic housing; › Connector pins: 68
Connectors with 2 chambers › ISO26262, AUTOSAR 4.2
Gasoline High Pressure Pump Diesel High Pressure Pump

GHP2.5 DHP1.1
ES
GHP optimized for Noise, Vibration, Harshness (NVH), Next generation of diesel common rail high pressure
robustness and efficiency. pump. Platform is basis for future pump applications.
› Robust design for worldwide fuel compatibility › Digital Inlet Valve (DIV ) supports low inlet pressure
Benefits
Benefits
for high efficiency and low noise
› Modular design for scalability and flexible
packaging › Best controllability and response
› Compact package and light weight
› Pressure: Up to 350 bar
› Digital Inlet Valve (DIV) technology › Pressure: Up to 2,500 bar
› Displacement : Up to 1.18 ccm / revolution › Displacement : 0.40 ccm / revolution
› Engine speed: Up to 7,500 rpm. › Weight : < 3 kg
› Inlet valve currentless open › Length: < 80 mm
› 600,000 start / stops › Drive: Belt, chain, gear
› Rotation: Clockwise, counter clockwise
› Radial 1-piston pump: 2 lobes / rev
Diesel High Pressure Pump Diesel High Pressure Pump

DHP2 DHP3
ES
Common rail pump for passenger cars and light duty Diesel high pressure pump with small size and light weight
vehicles. supporting common engine sizes.
› Compact package and light weight › Smart design for cam drive technology
Benefits
Benefits
› High lifetime › Reduced leakage behavior
› Worldwide fuel compatibility › Improved worst-case diesel capabilities
› Based on proven platform technology
› Pressure: Up to 2,200 bar
› Displacement : 0.58 ccm / revolution › Pressure: Up to 2,500 bar
› Weight : < 4 kg › Digital Inlet Valve (DIV) technology
› Length: < 80 mm › Displacement : 0.23 ccm / stroke
› Drive: Gear (belt, chain optional) › Weight : 800 g
› Rotation: Counter clockwise › Camshaft with up to 4 lobes possible
(clockwise optional)
› Radial 2-piston pump: 2 strokes / revolution
› Volume metering: Volumetric Control Valve (VCV)
Gasoline DI XL3.1 Gasoline DI XL5

Solenoid Injector Solenoid Injector
ES
Gasoline Direct Injection (GDI) injector for natural For natural aspirated and downsized turbocharged
aspirated and turbocharged engines. engines and future exhaust emission legislation.
› Improved linear flow range for high turbocharged › Euro 6c+ capable ( WLTP, RDE )
Benefits
Benefits
engines, suitable for side and central injection › For improved mixture preparation and combustion
› High flexibility of spray characteristics › Low temperature capable O-Rings or metal to metal
› Low temperature capable O-Rings connection
› Enhanced nozzle geometry for Euro 6c spray › Small packaging for downsized engines
performance › Worldwide fuel compatibility
› Worldwide fuel compatibility
› Pressure: Up to 350 bar
› Pressure: Up to 250 bar Technical Information
› Minimum dynamic flow: 1.5 mg /stroke at 200 bar

› Static flow range: Up to 20 g / s with controlled solenoid injection (COSI 2)
› Minimum dynamic flow: ~2.0 mg / stroke at 250 bar › Multiple injection: < 500 μs hydr. dwell time
with controlled solenoid injection (COSI) › Multi-stream technology: Max. 7 holes
› Multiple injection: < 800 μs hydr. dwell time › Nozzle hole drilling techn.: μEDM or Fs-Laser
› Multi-stream technology: Max. 7 holes › Valve tip diameter flexibility: 6.0 mm or 7.53 mm
› Nozzle hole drilling techn.: μEDM or Fs-Laser
Gasoline Deka 7/9 Gasoline Deka 10 Port

Port Fuel Injector Fuel Injector
ES
Flexible body, tip and spray configurations. Deka 9 with Provides high flow range and reduced packaging for
high flow range for turbocharged engines. twin and dual port engines.
› Various spray options and packaging configurations › Low minimum fueling with high linear performance
Benefits
Benefits
› Low minimum fueling with high linear performance and low voltage sensitivity
and low voltage sensitivity › Improved leakage and extended pressures
› Improved leakage capabilities › 23 mm length for non-automotive applications
› Pressure: 1 bar up to 9 bar › Pressure: 1 bar up to 10 bar
› Static flow rate: 0.95 g/s up to 6.0 g/s (Deka 7), › Static flow rate: 0.50 g/s up to 10.0 g/s
0.5 g/s up to 8.0 g/s (Deka 9)
› Linear flow range: >17:1 (SAE)
› SMD size: > = 50 μm
› Tip leakage: <1.8 μl / min (3 bar, Exxsol),
› Linear flow range: > 10 :1 (Deka 7), 15:1 (Deka 9) < 0.5 μl / min PZEV opt. available
› Spray patterns: Cone, bent and split › Spray atomization: > = 40 μm SMD
› Tip leakage Deka 9: < 1.8 μl / min (3 bar, Exxsol), › Spray patterns: Cone, bent and split
< 0.5 μl / min enhanced for
PZEV application › Flexibility major Ø: Standard 15 mm, slim 12.5 mm
› Fuel compatibility: Gasoline and flex fuel up to E100 › Fuel compatibility: Gasoline and flex fuel
up to E100 / M30
Diesel Piezo Common Rail Diesel Piezo Common Rail

Injector PCRs2 Injector PCRs5
ES
Diesel piezo common rail injector for passenger cars and New generation of servo-driven piezo common rail
light duty vehicles. injector with a field-proven piezo technology.
› Field-proven piezo technology › Reduced injector leakage for low CO2 emissions and
Benefits
Benefits
fuel consumption
› Reduced injector leakage for low CO2 emissions and
fuel consumption › Improved injection accuracy to meet
Euro 6 / US Tier 2 emission standards
› Improved injection accuracy to meet
Euro 6 / US Tier 2 emission standards › Low noise (NVH)
› No permanent leakage enables start / stop capability

› Minimum quantity: ≥ 0.8 mm³/stroke
› Minimum quantity: ≥ 0.8 mm³/stroke
› Multiple injection: Up to 7
› Multiple injection: Up to 7
› Min. injection separation: ≥ 200 μs
› Min. injection separation: ≥150 μs
› Total leakage: < 110 ml / min at 1,800 bar
› Total leakage: < 30 ml / min at 2,000 bar
(shift and permanent )
( no permanent )
› Diameter nozzle holes: ≥ 90 μm › Diameter nozzle holes: ≥ 90 μm
› Precise servo valve and needle control
Diesel Fuel Rail Gasoline

Fuel Rail Assembly
GDI
ES
PFI
Diesel fuel rails with flexible, proven and robust design Gasoline fuel rail
for a high variety of customer specific solutions. assembly for low and high pressure applications.
› System pressure up to 2,500 bar › GDI: Modular rail portfolio to support customer
Benefits
specific solutions clamped and suspended
› Integrated high pressure sensor
› Weight optimized rail architecture
› Pressure Decay Valve (PDV) as an option
› Pressure sensors optional
› 3 – 8 cylinder solutions
› PFI: Customer specific solutions available
› GDI: Fuel rail assembly up to 350 bar

Technical Information › Accurate injector orientation for optimal spray target
› PFI: Plastic and stainless steel fuel rails
› Fuel rail assembly up to 9 bar
› Optional internal damper
› E100 capability
LPG Liquefied Air Cooled SCR Injector

Petroleum Gas Injector
ES
Injector for LPG applications. Key technology in the area of NOX reduction to meet the
future emission legislations.
› Improved engine efficiency due to the liquid to › Single fluid airless system
Benefits
Benefits
vapor phase transition cooling effect
› Simple and reliable delivery of urea with excellent
› Low emission impact and reduced fuel spray performance
consumption due to appropriate liquid fuel metering
› Multiple spray configurations
› Reduced fuel line volume due to the liquid state
› Spray patterns: Cone, bent, elliptical
› System pressure: 3 bar up to 4 bar in gasoline,
› Sauter Mean Diameter (SMD): 70 μm up to 130 μm

up to 18 bar in LPG
(5 bar, AUS32)
› Static flow range: 0.95 g / s up to 5.0 g / s
› Fluid pressure range: 4 bar up to 9 bar
› Linear flow range: 11:1 (SAE )
› Max. injector body temp.: 150°C continuous
› Spray patterns: Various cones, bent, split
› Max. injector tip temperature: 200°C continuous
› Fuel compatibility: Gasoline, flex fuel and LPG
› Max. ambient temperature: 160°C continuous
› Tip leakage: 0.15 cc / min at 3.8 bar in air

Liquid Cooled SCR Injector Diesel Dosing

Injector
ES
Liquid cooled SCR dosing unit for NOX reduction in close The dosing system provides a simple and robust tech-
coupled applications. nology to deliver liquid diesel fuel into the exhaust path.
› Simple and reliable delivery of urea with excellent › Robust approach for Diesel Particle Filter (DPF ) and
Benefits
Benefits
spray performance High Efficiency NOX Trap (HENT) regeneration
› Multiple spray configurations (patented A² and › Uses existing injection technologies
enhanced atomizer options available) › Avoidance of oil dilution by post injection leads to
longer oil change intervals, greater tolerance of
› Spray patterns: Cone, bent, elliptical
biodiesel and increased engine durability

› Sauter Mean Diameter (SMD): 60 μm up to 130 μm › Higher degree of flexibility for regeneration timing
(5 bar)
Technical Information › Delivery fuel mass range: 0.1 g/s up to 6 g/s
› Fluid pressure range: 4 bar up to 9 bar
› Accuracy of flow: +/–7 %
› Max. injector tip temperature: 200°C continuous
› Sauter Mean Diameter (SMD): 75 μm up to 150 μm
› Max. ambient temperature: 200°C continuous
› Fluid pressure: 3.5 bar up to 12 bar
› Max. control valve temperature: 120°C
› Max. spray nozzle temperature: 500°C continuous
› System minimum pulse width: 10 ms up to 20 ms
Gasoline Turbocharger Gasoline Turbocharger

Steel Turbine Housing Aluminum Turbine Housing
ES
Design enables a fully automated assembly process. Robust and reliable design.
Design enables a fully automated assembly process.
› Robust and reliable design › Robust turbine /center housing connection with
Benefits
Benefits
patented tie-rod screws
› Matched system performance between turbocharger
and wastegate actuator › Optional RAAX™ turbine technology for best
transient response
› Applicable for hybrid applications
› Application specific wheel design for cutting edge
› High thermodynamic performance and low inertia
thermodynamics, drivability and best fuel economy

› Exhaust gas temperatures: Up to 1,050°C › Exhaust gas temperatures: Up to 1,050°C
› Milled compressor wheel › Maximum speed: 580 m / s
› Applications specific wheels for best fit of engine › Milled compressor wheel
design and charging efficiency
› Highly effective sealing system
› Highly effective sealing system
› Pneumatic and electrical wastegate actuation
› Pneumatic and electrical wastegate actuation › With electrical driven wastegate faster and precise
› Optional electrical compressor bypass valve and positioning of the wastegate especially near closed
electrical wastegate actuator from Continental position and accurate pressure regulation
SYN – Synerject 52 53
Synerject M3A Air Module

Engine Control Unit
SYN
Integrated
solution
The Non-Automotive business provides gaso- For 1 cyl., 2 and 4 stroke engines from 50 cc up to 250 cc
in light motorcycles, scooters, lawn mowers, generator sets.
line Engine Management Systems (EMS) and
components for Marine, Two-Wheeler, Recre- › ECU with integrated throttle body, ABV and sensors
Benefits
ation, Industrial, Lawn and Garden applications. › Uses Continental electronic and mechanical designs
› Easy mounting
› Throttle body size: Ø 16 mm up to 34 mm
› Versatile configuration, exists in stand-alone ECU
› ABV, TPS and TMAP sensor integrated

Technical Information › 16 bit microcontroller operating at 16 MHz
› 128 KB ROM (flash), 4 KB RAM
› IP66 and IP6K9K (high pressure cleaning)
› Input and output with full diagnostics and protection
› Operating temperature range: –20°C up to + 85°C
› 32 pin connector with spares for vehicle functions
› K-Line interface for diagnostics and reprogramming
M3B Air Module Engine M3C Engine Control Unit

Control Unit
SYN
For 1 and 2 cylinder, 2 and 4 stroke engines up to 1,000 cc For 1 and 2 cyl., 2 and 4 stroke engines up to 1,000 cc in me-
in motorcycles, scooters, lawn mowers, generator sets. dium to high end motorcycles, scooters, ATV, snowmobiles.
› ECU with integr. electronic throttle body and sensors › Uses Continental electronic and mechanical designs
Benefits
Benefits
› Uses Continental electronic and mechanical designs › Extended I / O for improved functionality
› Cost optimization and easy mounting › Enhanced timer module and control capability
› Different size of throttle body: Ø 26 mm up to 50 mm › Robust mechanics with aluminum casing
› Versatile configuration
› 16 bit microcontroller operating at 16 MHz
› Integrated TMAP sensor, ETC, monitoring unit
› 256 KB ROM (flash), 16 KB RAM

› 1 MB ROM (flash), 36 KB RAM
› Two knock sensor inputs
› Operating temperature range: – 40°C up to + 85°C
› Operating temperature range: – 40°C up to + 85°C
› 48 pin connector with spares for extended functions
› 32 pin connector with spares for vehicle functions
› CAN interface for diagnostics and reprogramming › CAN interface for diagnostics and reprogramming
M3D Ride by Wire Customized

Engine Control Unit Engine Control Unit
SYN
For 1 up to 4 cylinder, 2 and 4 stroke engines up to 1,600 cc For 1 or multiple cylinder, 2 and 4 stroke engines in all
in high end motorcycles, scooters, ATV, snowmobiles. types of non-automotive applications.
› Uses Continental electronic and mechanical designs › Small, efficient ECUs for V6 engines
Benefits
Benefits
› Drives mechanical or electrical throttle body › Uses Continental automotive electronic designs
› Modular and scalable system approach › Validated to customer specific requirements or
› Designed to meet Euro 5 with EOBD qualified to automotive standards
› From 24 pins up to 144 pins, automotive connector
› 896 KB ROM (flash), 2 KB E2PROM and 32 KB RAM › Plastic or aluminum housing
› IP67 and IP6K9k (high pressure cleaning) › For land and marine application environments
› Separate safety monitoring unit for ETC system › Configurable I / Os:

Analog inputs, K-Line or LIN or multiple CAN lines,
› Input and output with full diagnostics and protection multiple H-bridge, high current IGBT, high current
› Operating temperature range: – 40°C up to + 85°C output driver, knock interface, proportional
O2 sensor interface, etc.
› Double pocket 96 (32 + 64) pins CMC connector
› CAN interface for diagnostics and reprogramming
Mechanical Throttle Body Customized Electronic

Module Throttle Body
SYN
For medium and high-end motorcycles, scooters, ATV and For high-end motorcycles, scooters, ATV, snowmobiles.
snowmobiles. Suitable for off-road and on-road applications. Compatible with M3D ECU or other ride by wire ECU.
› Integrated stepper motor, TMAP sensor and injector › Core components from Continental Gen. 8 ETC
Benefits
Benefits
› Bore diameter from Ø 36 mm up to 50 mm › Contactless redundant magneto resistive sensor
› Flexible quadrant geometry and cable interface › Master-slave concept based on automotive safety
› Short bore length of 82 mm › Air channels designed to customer requirements
› Optional integration with fuel injector › Integration with fuel injector is optional
› Minimum idle flow at 40 kPa ∆P: 2 kg / h
› Minimum idle flow at 40 kPa ∆P: 2 kg / h
› Throttle position sensor linearity: +/– 2 % › Single TPS* linearity: +/- 1,5%
› Bypass flow: Up to 50 kg / hr › TPS* synchronous tolerance: +/- 3%
› Load exerted on cable at idle: 6N › TPS* hysteresis: < 0.1°
› Vibration level: 30 g › Response time of single throttle: < 90 ms (at 25°C)

› E-motor nominal supply voltage: 12 V
› Tamper proof adjusting screw for idle air flow
› Vibration level: 30 g
› Possibility to connect canister purge
› Operating temperature range: – 40°C up to +140°C
* Throttle Position Sensor
Strata Air Injector Electronic Oil Pump

Single or Multi Port
SYN
For 1 or multiple cylinder, 2 stroke engine applications. For 1 or multiple cylinder, 2 stroke engine applications.
Widely used in marine applications. Widely used in marine applications.
› Electromechanical valve › Fully flexible mounting location

Benefits
Benefits
› Combines air and metered quantities of fuel › In-tank or in-line
› Superior fuel atomization › Accurate oil delivery rate
› Generates spray for in-cylinder stratification
› Customized oil flow rate and number of outputs
› Gasoline, ethanol, kerosene, diesel, CNG compatible
› Full control of flow from 0 cc /sec up to 2 cc /sec
› Operating pressure : 70 kPa typical differential
› Control of flow by Pulse-Width Modulation

› Static flow rate (air): 0.10 g / sec up to 2.50 g / sec PWM / frequency input
› Dynamic 0.10 g / sec up to 0.90 g / sec › Full performance down to – 40°C
flow rate (air): at stroke, 0.05 mm up to 0.3 mm,
pressure 50 kPa up to 650 kPa
› Atomization: 4 SMD up to 28 SMD (μm) and
15 Dv up to 80 Dv, 0 up to 9 (μm)
› Coil resistance: 1.35 +/– 0.2 ( 27 AWG, 189 turns)
› Operating Voltage: 8 V up to 18 V
Customized Customized
Fuel Delivery Module Fuel Rail Assembly
SYN
For 1 or multiple cylinder, 2 and 4 stroke engines in all For 1 or multiple cylinder, 2 and 4 stroke engines in all
types of non-automotive applications. types of non-automotive applications.
› Metal and plastic flanges › Fully customized designs to meet any application
Benefits
Benefits
requirements
› Electrically conductive plastics
› Possible to integrate pressure sensors, diagnostic
› Fuel level sending units and low levels switches
ports, pressure regulators or pulsation dampers
› Integrated jet pump pulls fuel from hard-to-reach
› Plastic, brazed assemblies, extruded or forged
areas
aluminum designs
› Customized fuel line and electrical connector
› Validated automotive components

› Designed and validated to customer specific › Materials meet J1645 ESD requirements
requirements
› 100 % leak tests all fuel rail assemblies in the factory
› Can provide simple assembly as “pump-on-a-stick”
› Assemblies with integrated sensors, hoses, dampers
and regulators
› Designed and validated to customer specific
requirements
Ignition Coil Oxygen Sensor
SYN
For mopeds, scooters, light For 1 or multiple cylinder, 2 and 4 stroke engines in all
motorcycles, lawn mowers, electric power generators. types of non-automotive applications.
› Small sized inductive coil › Specifically developed for 2 wheeler environments

Benefits
Benefits
› High voltage diode integrated › A hermetic structure which uses injection current
pumping method against water splash
› Standard high voltage connector
› Resistant to water droplets
› Standard primary connector
› Vibration resistance
› Nominal voltage supply: 14 V + 0.5 V
› Lead wire: 4 wire

› Maximum primary current : 3.3 A
› Cable length: 500 mm
› Dwell time: < 6 ms
› Body length: 35 mm
› Arc duration (1,000 V Zener): 0.5 ms + 0.2 ms
› Thread size: M12
› Recommended cable size: 2.0 mm2 up to 2.5 mm2
› Reference air: Self pumping
› Recommended
cable overall diameter: 2.5 mm2 up to 3.5 mm2 › Heater resistance: 8.1 ohm
HEV – Hybrid Electric Vehicle 66 67
Hybrid Electric
Vehicle
12 V Power Net System 12 V Dual Battery Manager
HEV
Supports the 12 V board net and supplies additional Stabilizes 12 V boardnet by connecting two energy
energy for stop-start, and during engine idle and coasting. storages and supports numerous functions.
› Voltage stabilization during high power needs › 4% fuel savings on top of stop-start savings
Benefits
Benefits
› Flexible regulation of starter current or voltage or › Extended stop-start (< 20 km/h)
power
› Recuperation
› Double Layer Capacitor (DLC) energy storage for
high number of load cycles › Engine-off coasting
› Dampens transient pulses with fast DC/DC control › Stabilized boardnet

logic and DLC
› Switch Technology: MOSFET
› Second power source – serial connection to vehicle Technical Information
› Max. voltage drop: 50 mV

battery
› Continuous current : 180 A
› Current capability up to 1,200 A
› Peak current: 1,000 A
› Regeneration with integrated 150 W DC/DC
› Temperature range: – 40°C up to +105°C (ambient )
› Energy storage with DLCs (5.2 V, 600 F )
› Very low impedance of power path:
1.6 mOhm at 20°C
48 V Belt-driven 48 V DC /DC Converter

Starter Generator
HEV
Efficient electric motor with integrated inverter realizes Stabilizes and connects the 12 V and the 48 V power net
advanced stop-start, coasting and electric boost. for advanced stop-start, coasting and electric boost.
› Reduces fuel consumption by 13% › Bi-directional DC /DC converter 48 V – 12 V

Benefits
Benefits
› Integrated inverter, no external connectors and wires › 12 V board net stabilization
› Fast engine start › Pre-charging function for 48 V DC link
› Recuperation › Self-protection based on diagnosis und limitation
› Engine-off coasting › Digital voltage and current control
› Maintenance free – no slip rings, no debris
› Power (buck) : Up to 3 kW permanent
› Induction machine, fluid cooled Technical Information
› Current (permanent) : 215 A buck, 58 A boost

› Torque: 150 Nm at crank shaft
› Efficiency: > 95%
› Power (mechanical) : 14 kW peak
› Air-cooled
› Power (regen.) : 16 kW peak
› Speed: Up to 20,000 rpm continuous
48 V Battery Management HV Axle Drive with

System integrated Inverter
HEV
System is integrated into the battery, balances and Developed for pure electric driving, also applicable in
operates battery cells individually under safe conditions. full hybrid and plug-in hybrid vehicles.
› Complete circuitry on one single PCB › E-motor, inverter and differential in one housing
Benefits
Benefits
› Measurement of voltage, current and temperature › 15 % weight reduction
› Crash signal sensing and reaction › Less cables and less connectors
› Contactor control and pre-charge function › Less cooling connections
› Calculation of state of charge (SOC), › Available as permanent magnet or induction
state of function (SOF) and state of health (SOH) machine
› Supervises up to 13 cells Technical Information › High speed : Up to 12,000 rpm

› Quiescent current : < 100 μA › High voltage: Up to 450 V

› Measurement range: › Mechanical power: 60 kW continuous, 130 kW peak
– Cell voltage: 1.5 V to 5 V › Torque: 350 Nm max
– Temperature: – 40°C to +90°C
– Battery current: +/– 400 A › Light weight : 88 kg (motor, inverter,
differential)
› Fluid cooling
HV Power Electronics (Inver- HV Inverter

ter with DC /DC Converter)
HEV
Drives the e-machine in both motor and generator mode. Drives a High Voltage (HV) e-machine in both motor and
Supplies the 12 V boardnet with electric power. generator mode.
› State of the art power electronics › Compact and low inductive mechanical design
Benefits
Benefits
› Compact and robust design › Highly integrated driving circuit
› Very high power density › Use of Multi Core μC (ASIL D certificated)
› For application in hybrid and electric vehicles › Increased robustness against EMC
› Fluid cooled system › Output power: Up to 330 kVA at 450 V
› Inverter output power: Up to 250 kVA at 450 V › Voltage: 170 V to 470 V

› Accurate control of motor torque and power flow › Coolant temp.: 85°C
› DC/DC converter output power: 3 kW › Integrated HV EMC filter
› Bi-directional link between HV traction battery › ASIL C compliant
and conventional 12 V board net
HV DC/DC Converter Powertrain

Electrification Solutions
Converts voltage from High Voltage (HV) battery

to 12 V board net and vice versa.
› Conversion HV to 48 V also possible

Benefits
› DC / DC power scalable (parallel power phases)

› Use of Multi Core μC (ASIL D certificated)
› Uni- and bidirectional operation
› Voltage, current and temperature monitoring
› Reverse polarity protection by external fuse
› Output power: 3 kW
› Current : 200 A at 14 V
› Max. peak current : 275 A at 14 V, 10 sec
› Input voltage: 170 V to 460 V
› LV output voltage: 6 V to 10 V (buck mode)
TR – Transmission 78 79
Transmission
Control Unit for Control Unit for

Double Clutch Transmission Double Clutch Transmission
TR
Integrated transmission control unit for dry 7-speed Integrated transmission control unit for wet 7-speed
Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).
› Mechatronic module integrated in the gearbox › Mechatronic module integrated in the gearbox
Benefits
Benefits
› Direct connection of actuators to the control unit › Integrated in transmission and surrounded by
transmission oil
› Higher reliability of the electronics due to the
reduced number of internal connections › Short links to sensor systems and actuating
elements
› Reduced weight
› Reduced harness length
› Ceramic substrate technology
› LTTC (Low temperature co-fired ceramics) substrate

› Operating temperature: – 40°C up to +140°C Technical Information
for electronic components
› 32-bit microcontroller
› Operating temperature: – 40°C up to +145°C
› Sensors: 4 gearshift position, 2 clutch position,
3 speed, 1 pressure, 1 temperature
› Sensors: 4 gearshift position, 2 speed, 2 pressure,
› Actuators: 8 x PWM proportional solenoids
1 temperature
› Control of BLDC motor of oil pump
› Actuators: 11 closed-loop controlled valves
› Only one plug connection to the vehicle

TR
Integrated transmission control unit for wet 7-speed Integrated transmission control unit for wet 7-speed
Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).
› Front, all-wheel and hybrid drive applications › All-wheel and front-wheel drive applications
Benefits
Benefits
› Longitudinal installation of the engine › Longitudinal installation of the engine
› Small space requirements › Fully integrated control unit contains all electronic
components
› Alignment of electronics and mechanics in the unit
› Improved shifting performance and comfort
› Short links to sensor systems and actuating elements
› BD-HDI substrate technology

› Operating temperature: – 40°C to +148°C
› 2 x 32-bit microcontroller
› Sensors: 4 gearshift position, 10 position, 3 speed,
› Sensors: 2 temperature, 1 motor speed, various
2 pressure, 3 temperature, 1 PLCD module
external sensors
› Actuators: 11 solenoids
› Actuators: 9 solenoids (+ 1 optional),
hydraulic pump motor › Vibrations up to 20 g
› ASIL-D

TR
Integrated transmission control unit for wet 7-speed Integrated transmission control unit for
Double Clutch Transmission (hydraulically controlled). wet 6-speed Double Clutch Transmission.
› Module integrated in transmission › Mechatronic module integrated in the gearbox

Benefits
Benefits
› Short links to sensor systems and actuating › Directly mounted on valve body
elements
› Weight reduction due to integration
› Simple car wire harness
› Improving shifting performance and comfort
› Small space requirements
› Thickfilm and ceramic substrate technology

› Sensors: 4 linear position, 2 speed, 2 pressure,
› Sensors: 4 gearshift, 1 parking lock, 3 speed, 2 temperature, 1 transmission range
2 temperature, 2 pressure
› Actuators: 9 solenoids (4 prop. + 5 on /off )
› Actuators: 10 solenoids, 1 BLDC motor for oil pump

TR
Mechatronic actuator External transmission control unit for wet 7-speed
module for dry 6-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).
› Directly attached to the gearbox › Stand-alone module placed in vehicle cabin

Benefits
Benefits
› Includes 2 BLDC motors › Controls fully automatic shifting program
› Higher reliability and accuracy of control › Sports mode with improved shifting dynamics
› Flexible transmission design in regards to package › Simple integration into vehicle
› High dynamics of integrated gear shift actuators
› Improved shift comfort
› PCB substrate technology

› Operating temperature: – 40°C up to +115°C Technical Information
› Operating temperature: – 40°C up to + 85°C
› Sensors: 5 temperature, 2 shift motor position
› Sensors: 3 speed (frequency), 3 pressure (analog),
› Power supply for external sensors
2 temperature (analog), 4 displacement (PWM)
› Actuators: 2 BLDC motors for gear changing
› Actuators: 9 solenoids (7 closed loop + 2 open loop)
› Integrated control for 2 external BLDC motors
› PCB screwed on aluminum plate
› Modular software design

TR
Universal transmission control unit for 7-speed External transmission control unit for dry 7-speed
Double Clutch Transmission. Double Clutch Transmission.
› Control unit for a double clutch transmission › Compact module with small size and low weight
Benefits
Benefits
for hybrid vehicles › Engine / passenger compartment mounted
› Contains electromechanical actuation and smart › Enables smooth gear shifting
actuators
› Robust mechanics with aluminum casing
› Stand-alone module placed in engine compartment
› Optimized cooling surface
› PCB-FR4 technology
› 3 motor supply voltage

› 32-bit microcontroller with internal flash memory
› Sensors: 2 x 3 hall, no external sensors › Sensors: 3 x 4 motor hall, 2 select postion, 2 speed,
› Actuators outputs: 2 B6 drivers for EC motor, TSG sensor
2 HS driver enable function › Actuators: 4 BLDC motors, 2 select solenoid
› Communications with 3 high speed › PCB substrate, SMD
CAN connections and 1 LIN connection
› 2 CAN port, Flex-ray
Control Unit for Control Unit for Stepped

Double Clutch Transmission Automatic Transmission
TR
Transmission control unit platform Integrated electro-hydraulic transmission control module
for Double Clutch Transmission application. for 6-speed Stepped Automatic Transmission.
› AUTOSAR standard architecture › Integrated TCU including manifold and solenoids

Benefits
Benefits
› ISO26262 ASIL C compliance › Compact module with small size and low weight
› Compatible with stand-alone and attached-to › Higher reliability and reduced number of connectors
concepts
› Reduced calibration effort in transmission plant
› Cost and weight optimized solution
› Enables smooth gear shifting
› Small size LTTC (low temperature co-fired ceramics)

substrate for electronic components
› Up to 12 closed loop current control outputs
› 32-bit microcontroller with external flash memory
› BLDC control
› 11 analog inputs and 7 digital inputs › Actuators: 7 integrated solenoids, 4 integrated pres-
sure switches, integrated hydraulic filter elements
› 4 voltage or current type frequency inputs
› Plastic mechatronics with integrated lead frames
› 2 independent 5 V sensor supplys and
2 independent 8 V sensor supplys › Integrated hydraulic manifold
Control Unit for Stepped Control Unit for Stepped

Automatic Transmission Automatic Transmission
TR
Integrated control unit for 7-speed Stepped Automatic External control unit for 5-speed Automatic Transmissions
Transmission. in rear-wheel drive vehicles.
› Mechatronic module assembled on valve body of › Stand-alone control unit

Benefits
Benefits
gearbox
› Simple integration into vehicle
› Fully integrated control unit contains all electronic
components › Improved shift comfort
› Short links to sensors and actuating elements › Robust plastic cover
› Improved performance characteristics
› Small size BD-HDI substrate for electronic parts › Operating temperature: – 40°C up to +140°C
› Operating temperature: – 40°C up to +140°C › 16-bit microcontroller

› 32-bit microcontroller › Power output for 6 electro-mechanical hydraulic
› Sensors: 3 speed, 1 temperature, 1 linear position valves
› Optional plugs for external pressure sensor › Actuators: 2 valves for hydraulic of transmission,
› Actuators: 8 power outputs for solenoids 3 valves for gear changing, 1 valve for bypass
converter
› Plastic mechatronic with solenoid fixation system
› Flexible printed circuit (FPC)
Control Unit for Stepped Control Unit for Stepped

Automatic Transmission Automatic Transmission
TR
Stand-alone transmission control unit for 6-speed Universal transmission control unit for Stepped Automatic
Stepped Automatic Transmission. Transmission.
› Compact module with small size and low weight › Chassis mounted control unit
Benefits
Benefits
› Engine / passenger compartment mounted › Flexible module with various sensor inputs and
› Enables smooth gear shifting actuator outputs
› Universal use
› Compact size stand-alone transmission control unit
› PCB (FR4) substrate technology
› 32-bit micro processor with internal flash memory › Operating temperature: – 40°C up to +105°C
› 2 power supply outputs to drive solenoid › 32-bit microcontroller
› 6 linear solenoid and 2 on / off solenoid driving › Sensors: External
outputs
› Actuators: Control of 8 PWM solenoids
› 4 coded type position and sport mode inhibitor
› Sealed housing
switch inputs
› Oil temperature sensor and 2 speed sensor inputs
› K-line and 500 kbps CAN communication
Control Unit for Stepped Control Unit for Continuously

Automatic Transmission Variable Transmission
TR
Universal transmission control unit Integrated transmission control unit
for Stepped Automatic Transmission. for Continuously Variable Transmission.
› External control unit › Front wheel drive application

Benefits
Benefits
› Flexible module with various sensor inputs and › Longitudinal installation of the engine
actuator outputs
› Small space requirements
› Universal use
› Improved performance characteristics
› Sensors: External
› Sensors: 1 temperature, 1 position motor
› Actuators: Control of 10 PWM solenoids
› Control of various external sensors
› Sealed housing
› Actuators: Control of 11 solenoids for
transmission ratio
› Vibrations up to 20 g
Control Unit for Continuously Control Unit for

Variable Transmission Commercial Vehicle
TR
Integrated transmission control unit External transmission control module for various
for Continuously Variable Transmission. commercial vehicle transmission applications.
› External module placed in passenger or engine › Control module for ultrashift and autoshift
Benefits
Benefits
compartment applications in commercial vehicles
› Stand-alone concept › Designed as AMT controller
› Size and weight optimized › Stand-alone module, transmission mounted
› Reduced time-to-market due to platform technology › Fuel economy and reliability benefits
› PCB substrate technology › Flex FR4 PCB substrate technology

› Operating temperature: – 40°C up to + 95°C Technical Information › Operating temperature: Up to +105°C

› 32-bit microcontroller with external flash memory › 32-bit microcontroller
› Sensors: 5 gearshift position, 3 gearlever control, › Sensors: 3 position, 3 speed
› Actuators: 4 motor control
› Actuators: 6 PWM proportional solenoid
› 76 way module I / O connector
› Closed-loop control
› Communications via Hardwire and CAN
Control Unit for Control Unit for Double

Commercial Vehicle Clutch Transmission (CV)
TR
Transmission control unit for commercial vehicle TCU for 7-speed Double Clutch Transmission.
automated transmission. Direct mount TCU with pass through connector.
› Control unit for automated transmissions for › Measurement of clutch speed (input shaft )
Benefits
Benefits
heavy duty trucks
› Measurement of output speed and direction
› External module directly attached to pneumatic
› Measurement of transmission temperature
actuator, which is mounted on the gearbox
› Control and measurement of clutch pressure
› Improved fuel economy
› Substrate Technology: PCB substrate technology
› DCB (Direct Copper Bonded) and LTCC
(Low Temperature Co-fired Ceramics) technology › Operating Temperature: – 40°C up to +125°C

› Operating temperature: – 40°C up to +140°C › Microprocessor: 32 bit MPC5674F with 4 mb of RAM
› Sensors: 5 speed, 1 temperature, 1 pressure, › Control of 4 gearshifts and positions
5 external sensor supply
› Control of 2 safety valves
› Actuators: 15 control of pneumatic valves
› Control of main oil pressure
› Control of cooling oil pressure
EAST Transmission Control Unit for

Control Unit Platform Limited Slip Coupling
TR
Transmission control unit platform for DCT-, CVT-, AMT- Control unit for limited slip coupling of 4WD control
and Step-AT applications. applications.
› External module placed in passenger or engine › Unit directly attached to 4WD coupling
Benefits
Benefits
compartment
› Controls valve and feeder pump to change torque
› Stand-alone concept distribution between front and rear axle
› Cost and weight optimized solution › Contribution to improve traction and stability of
› Reduced time-to-market due to platform technology the vehicle
› PCB substrate technology › PCB substrate technology
› Operating temperature: – 40°C up to + 95°C › Operating temperature: – 40°C up to +120°C

› 32-bit microcontroller with external flash memory › 16-bit microcontroller
› Sensors: 4 gearshift position, 4 gear lever position, › Sensors: 1 pressure sensor, 1 oil temperature sensor
› Actuators: PWM control of 2 proportional valves,
› Actuators: 8 PWM proportional solenoid closed loop 1 feeder pump motor
control (hydraulic version), 3 motor control (electric
version)
› With integrated BLDC-motor control
Control Unit Multi Position

for Transfer Case Linear Actuator
TR
Integrated transfer case actuator (electric motor and Power transfer control unit.
control unit ).
› 4WD / AWD control unit with integrated motor for › Axle disconnect and AWD function
Benefits
Benefits
wet transfer-cases, directly attached to the transfer
› 1 and 2 speed system configurations
case
› Mounted on PTU / RDU on the axles
› Integration of ECU, brushless DC motor and sensors
in one mechatronic actuator unit › Covers heat stake interface to PCB
› Motor terminal blades on PCB
› Operating temperature: – 40°C up to +140°C (TC) › FR4 substrate

› 16-bit microcontroller › Operating temperature: – 40°C up to +125°C
› Sensor: 1 angle position sensor › Microprocessor: FSL S12XS
› Actuator: 1 BLDC motor integrated in XCU › Sensors: 8 linear hall effect (shift fork position
feedback), 1 quadrature rotational encoder
(motor rotation feedback), 1 temperature
› Actuators: Control of 1 brushed DC motor
Direct Shift Module Sensorcluster for Automatic

Transmission Applications
TR
DSM offers a shift-by-wire function for the PRND selection Sensor Cluster
of an automatic transmission. for DCT-, CVT-, AMT- and Step-AT-Applications
› Shift-by-Wire module attached outside of the › Internal module integrated in the transmission
Benefits
Benefits
gearbox, at the housing of the 7-speed AT torque
› Can be used as stand-alone system
converter
(with various TCUs)
› Shift-by-Wire PRND module is smaller in size
› Cost and weight optimized solution
compared to conventional PRND shift levers.
This creates more space for other CUs. › Stand-alone sensor cluster (smart or non-smart )
› High temperature PCB › PCB substrate technology

› Operating temperature: – 40°C up to +120°C Technical Information › Operating temperature: – 40°C up to +150°C
› 16-bit microcontroller › Sensors: 4 gearshift position, 2 speed, 1 temperature
› Sensors: Lever angle, temperature, eccentric shaft › Provides sensor signals to separate TCU
› Actuators: 2 motors for PRND shift and emergency
shift to P function
› Communications via CAN
S & A – Sensors & Actuators 108 109
Sensors
& Actuators
S & A – Actuators 110 111
Active Purge Air Control Valve

Economy Line S11.1
Generates the flow of fuel vapors from an evaporative emis- Intake air flow and pressure control on combustion
sion canister to the manifold of limited vacuum engines. engines. Supports EGR and particle filter regeneration.
S&A
› HC purging is independent from manifold vacuum › Low cost – full functional range
Benefits
Benefits
› OBD monitoring for HC evaporative leak detection › Capable for LP EGR environment
› Pressure sensing › Low weight, small package
› Low power consumption (25 W max) › Good crash behavior
› Compact size for vehicle packaging › Non-contacting position sensor
› Radial pump with integrated electronics › Temperature range: – 40°C up to +140°C

› Purge flow: 50 SLPM min and › Response time (typ.): 110 ms (13.5 V, RT)
8 kPa at 12 V and 20°C
› Pressure range: Up to 3.5 bar peak
› TP diameter range: 40 mm to 57 mm
› Brushless DC motor: 25 W max
› Signal output: Analog 5 V or digital SENT
› Feedback for speed and torque
Air Control Valve Air Control Valve

Economy Line S11.2 Performance Line S6
Intake air flow and pressure control on combustion Intake air flow and pressure control on combustion
engines. Supports EGR and particle filter regeneration. engines. Supports EGR and particle filter regeneration.
S&A
› Low cost – full functional range › High torque – fast performance
Benefits
Benefits
› Capable for LP EGR environment › Capable for LP EGR environment
› Low weight, small package › Very good EMC performance
› Non-contacting position sensor › Non-contacting position sensor
› Temperature range intake air: – 40°C up to +140°C › Temp. range intake air: – 40°C up to +140°C
› Temperature range environm.: – 40°C up to +160°C › Temp. range environment : – 40°C up to +160°C
› Response time (typ.) : 110 ms (13.5 V, RT) › Response time (typ.): 90 ms (13.5 V, RT)
› Pressure range: Up to 3.5 bar peak › Pressure range: Up to 3.5 bar peak
› TP diameter range: 40 mm up to 68 mm › TP diameter range: 40 mm up to 68 mm
› Signal output : Analog 5 V › Signal output : Analog 5 V
or digital SENT or digital SENT
Air Control Valve Air Control Valve – Perform.

Performance Line S6 HT Line S8.6 (MD/HD Truck)
Intake air flow and pressure control on combustion Intake air flow and pressure control on combustion
engines. Supports EGR and particle filter regeneration. engines. Supports EGR and particle filter regeneration.
S&A
› Capable for high temperature applications › Modular capable for 12 V and 24 V systems
Benefits
Benefits
› High torque - fast response › Capable for big TP diameters – high flow
› Very good EMC performance › Non-contacting position sensor
› Capable for LP EGR environment
› Temperature range: – 40°C up to +140°C
› Non-contacting position sensor
› Response time (typ.): 90 ms (13.5 V, RT)
› Temp. range intake air: – 40°C up to +230°C › Pressure range: Up to 3.5 bar peak
› Temp. range environment : – 40°C up to +160°C › TP diameter range: 57 mm up to 100 mm

› Response time (typ.) : 90 ms (13.5 V, RT) › Signal output : Analog 5 V
› TP diameter range: 40 mm up to 68 mm
› Signal output : Analog 5 V
or digital SENT
Air Control Valve Brushless DC Drives

Smart ACV High Efficiency
Intake air flow and pressure control on combustion Best performance motors to reasonable prices for different
engines. Supports EGR and particle filter regeneration. use out of a scalable, modular concept.
S&A
› Integrated control unit with processor and H-bridge › High efficiency brushless DC drives for use in
Benefits
Benefits
for DC motor on-board double clutch, AWD-disconnect, oil pumps etc.
› Easy to integrate into existing systems › Small package, low weight, low inertia
› Capable for LP EGR environment › Low content of rare earth material
› Non-contacting position sensor › High torque as well as high speed capability within
the modular concept
› Temperature range: – 40°C up to + 120°C
› Different performance classes: 50 W up to 900 W

› Response time (typ.) : 150 ms (13.5 V, RT) Technical Information
› Variation of diameter, length and windings
depending on customers’ needs
› TP diameter range: 57 mm up to 80 mm
› Temperature range: – 40°C up to + 140°C
Canister Purge Solenoid Digital Linear Actuator

CPS6 Compact Size – Gen VII
The Canister Purge Solenoid controls hydrocarbon Idle Airflow control for 2-wheeler and small engines.
vapors from the canister to the intake manifold.
S&A
› Higher flow than competitive valves › Accurate and stable idle air control
Benefits
Benefits
› Linear flow curve and fast response › Various gas (air) flow curve can be achieved
› Sonic nozzle flow control › Light weighted and small sized robust design
› Integrated particle trap to control contamination › Dedicated for 2W and small engine application
› High resolution linear positioning against load
› Integrated noise attenuation volume
› Two packagings for different integration options
› Flow at >30 kPa: 110 SLPM (2.3 g / s, 7.9 kg / h)
› Operating voltage: 7.5 V up to 14 V

› Operating voltage: 9 V up to 16 V (13.5 V optimal) Technical Information
› Inductance /winding: 20.7 mH
› Coil resistance: 21 Ohms
› Resistance /winding: 53 Ohms
› OBD leakage (6.7 kPa vacuum on canister port ): › Resolution: 0.042 mm /step ( full step mode)
< 3.0 SCCM
› Total travel (typ.): 8.5 mm (204 steps)
› Operating temp.: –25°C up to +125°C
› Operating temp.: – 30°C up to +110°C
› Frequency: 5 Hz up to 32 Hz
› Airflow control: Up to 41.8 kg /hr
(10 Hz recommended)
at ΔP = 600 hPa
Digital Linear Actuator Digital Linear Actuator

Standard Size – Gen I Standard Size – Gen II
Accurate and precise gas / airflow. Accurate and precise gas / airflow.
Linear position control against external load. Linear position control against external load.
S&A
› Accurate and stable idle air control › Accurate and stable idle air control
Benefits
Benefits
› Various gas (air) flow curve can be achieved › Various gas (air) flow curve can be achieved
› High accuracy under severe conditions › High accuracy under severe conditions
› Proven reliability and long durability › Proven reliability and long durability
› High resolution linear positioning against load › High resolution linear positioning against load
› Operating voltage: 12 V (7.5 V – 14 V) › Operating voltage: 12 V (7.5 V – 14 V)

› Resistance per winding: 53 Ohms › Resistance per winding: 48 Ohms

› Linear resolution: 0.042 mm / full step › Linear resolution: 0.042 mm / full step
› Total travel (typical) : 8.5 mm (204 steps) › Total travel (typical) : 8.5 mm (204 steps)
› Operating temperature: – 40°C up to +125°C › Operating temperature: – 40°C up to +125°C
› Vibration capability: Up to 40 G › Vibration capability: Up to 40 G
› Life time durability: 500 hours › Life time durability: Up to 2,000 hours
› Weight : ~110 g › Weight : ~ 90 g
Digital Linear Actuator Electrical Compressor

Standard Size – Gen V Bypass Valve
Accurate and precise gas / air flow. Compressor surge prevention and turbocharger lag
Linear position control against external load. reduction by opening a bypass for the compressor.
S&A
› Accurate and stable idle air control › Electromagnetic on-off solenoid
Benefits
Benefits
› Various gas (air) flow curve can be achieved › Improved performance and size
› High accuracy under severe conditions › No vacuum lines, tank, or vacuum control valve
needed
› Proven reliability and long durability
› Fast actuation
› Plastic sleeve gives lighter weight
› Mounted directly on turbocharger or air duct
› Operating voltage: 12 V (7.5 V – 14 V)
Technical Information › Nominal operating voltage: 12 V

› Linear resolution: 0.042 mm / full step
› Response: < 50 ms at 20°C; 13.5 V
› Total travel (typical) : 8.5 mm (204 steps)
› Operation (gas) temperature: – 40°C up to +200°C
› Vibration capability: Up to 35 G
short term (30 min): +200°C
› Life time durability: Up to 1,000 hours
› Ambient temperature: – 40°C up to +150°C
› Travel: ≥ 5 mm; Poppet
diameter 26 mm
Electrical Exhaust Gas Electrical Wastegate

Recirculation Valve Actuator
Controls the amount of recirculated exhaust gas to reduce Performing waste-gate adjustment to optimize functional
NOX emissions and fuel consumption. application and reduce fuel consumption.
S&A
› Electric actuation has faster response and more › Continuous adjustment of external application using
Benefits
Benefits
control than conventional vacuum systems rotating output shaft

› Eliminates vacuum regulator and connecting hoses › Ideal for use in turbocharger applications
› Can be tailored to customer flow requirements › Option: Default position
› Permanent feedback signal (non-contacting)
› Current consumption
at max. flow: 1.0 A at 20°C › Max. external load

› Nominal operating voltage: 12 VDC without return function: 92 Ncm
› Max current consumption: 1.5 A › Max. continuous holding torque without
return function at 160°C: 144 Ncm
› Nominal coil resistance: 8.0 Ohms at 20°C
› Holding torque
› Nominal operating frequency: 90 Hz up to 175 Hz capability at 160°C: 420 Ncm
› Position sensor supply voltage: 5 VDC › Response time less than: 140 ms / 80°angle at 160°C
› Response time (total stroke): < 50 ms at 20°C, › Operation temperature : – 40°C up to +160°C
13.5 VDC
Electronic Throttle Control Exhaust Control Valve

ETC 12 High Pressure
Torque / load control on gasoline combustion engines. Helps to reduce emissions of NOX and fuel consumption
Supports idle speed, cruise and traction control. in gasoline and diesel engines in HP EGR loop.
S&A
› High performance throttle body actuator › Balanced rotary throttle principle for EGR control
Benefits
Benefits
› High torque, fast response › Contactless MR Sensor, flexible output
› Low weight, very small package › Provides accurate low flow precision
› Low leakage, spherical bore optional
› High flow EGR with low gas pressure drop
› Capable for turbo and supercharged applications
› Fits high temperature and pressure pulsations
› Optional capable for high temperature applications
› Torque at flap: 230 Ncm
› Temperature range: – 40°C up to +140°C /180°C
› Response time (typ.) : 90 ms (13.5 V, RT) › Response time (85 %): < 80 ms
› Pressure range: Up to 3 bar peak › Nominal supply voltage: 12 V DC or 24 VDC
› Leakage (at stop) : < 1.7 kg /h (52 mm) › Position sensor supply voltage: 5 V DC
› TP diameter range: 40 mm up to 95 mm › Maximum flow: Up to 190 kg / h
› Analog or digital (SENT) position feedback at 50 hPa
› Weight : 490 g (TP 48 mm with › Exhaust temperature: Up to 700°C
optimized housing)
Exhaust Control Valve Exhaust Control Valve

Linear Low Pressure
Helps to reduce emissions of NOX and fuel consumption in Helps to reduce emissions of NOX and fuel consumption
gasoline and diesel engines. in gasoline and diesel engines in LP EGR loop.
S&A
› Linear technology (direct position measurement ) › High flow LP EGR valve with small pressure drop
Benefits
Benefits
› Reduced friction and short response time › Non-contacting sensor, flexible output, not sensitive
against magnetic fields
› Low valve seat leakage
› Compact, light weighted size
› Compact, can be customized
› Adapted to corrosion requirement for LP EGR path
› Suitable for high temperature applications
› Response time (t90): < 90 ms
› Nominal supply voltage: 12 V DC
› Nominal supply voltage: 12 V DC

› Position sensor supply voltage: 5.0 V DC
› Position sensor supply voltage: 5 V DC
› Exhaust gas temperature: > 500°C with
adequate cooling › Maximum flow (at dP 20 hPa): 245 kg / h
› Typical ratio of pintle Ø to lift: 4 to 1 › Internal leakage (at dP 600 hPa): ≤ 3 kg / h
› Response time (t85): ≤100 ms › Exhaust gas temperature: 100°C up to 200°C
Latching Valve Linear Purge Valve
Latching refueling valve is a bi-stable valve used to a seal- The Linear Purge Valve controls hydrocarbon vapors from
pressurized tank or isolated HC vapors in a normal tank. the canister to the intake manifold.
S&A
› Significantly less energy consumption › Very low operating noise
Benefits
Benefits
› Maintains valve position using zero current draw › Fast response for incremental flow control at all
operating conditions
› Very low flow restriction
› Excellent low end flow control preventing unwanted
› Able to determine valve position (open /closed)
surges of fuel vapor
› Passive relief function for fuel tank over pressure
› Typical flow: 70 SLPM at 57 kPa
› 14 V DC pulse for < 100 ms to change valve state
› Operating voltage: 14 V
› Flow: >115 SLPM at 1.5 kPa
› Coil resistance: 14.0 Ohms
› Overpressure relief at 43.5 kPa
› Maximum current: 500 mA
› Leak: < 1 sccm at 5 kPa and 20 kPa tank pressure
› Control circuit
› Leak: < 3.5 sccm at 35 kPa tank pressure constant current at: 150 Hz up to 200 Hz
› Leak: < 10 sccm at – 9 kPa tank pressure › Weight: 200 g
Natural Vacuum Leak Pump –

Detection (NVLD III) Electrical Water Pump
Engine off OBD monitoring for hydrocarbon evaporative Volume flow-rate on demand for engine and power
leak detection. Legislation compliance. electronics cooling as well as turbocharged air cooling.
S&A
› With integrated electronics › Supports energy management (on demand)
Benefits
Benefits
› OBD HC leak diagnostic performed after key off › Operation independent from main cooling circuit
› Integrated solenoid for improved purge flow capacity › Operation independent from combustion engine
operation
› Temperature sensing; Switch sensing
› Timer function › Electronically sensorless field oriented commutated
BLDC motor
› Detection capable to 0.5mm diameter leak
› Wet running permanent magnet rotor

› Bit serial communication with ECU
› Modular design concept
› High in use monitor perform.: Ratio (IUMPR >100 %)
› Volume flow: 700 l / h up to 1,800 l / h
› Nominal coil resistance: 21 ohms
› Differential pressure: 500 hPa up to 900 hPa
› Electrical power: Max. 110 W
› 100 SLPM purge flow: < 6 mbar ∆ pressure
› Hydraulic power: 10 W up to 45 W
Pump – Turbo Purge Valve

Twin Drive Pump
Gearboxes and combustion engines with hydraulic The Turbo Purge Valve controls HC vapors from the
demand for start-stop and hybrid functions. canister to the turbo charged intake manifold.
S&A
› Combined mechanical and electrical driven › EVAP turbo system cost savings
Benefits
Benefits
main pump
› Smooth start-to-open characteristics
› No need for adding electrical and mechanical power
› Robust design and easy to calibrate
by pinions
› Multiple turbo purge system parts in one assembly
› Operates simultaneously or separate in mechanical
and /or electrical mode › Flexible configuration using common actuator
› Highest overall efficiency in both operation modes
› Incorporates check valves to protect purge system
› Electronically commutated BLDC motor › Operating voltage: 9 V up to 16 V (13.5 V optimal)
Techical Information
with / without sensor

› Operating temp.: –25°C up to +125°C
› Electric power: ~150 W up to 500 W
› Operating pressure: Up to 400 kPa
› BLDC commutation, depending on customer
› Frequency: 5 Hz up to 30 Hz
requirement
(10 Hz recommended)
› Vane-type pump
› Purge flow: 110 SLPM
Variable Turbine Geometry Door Handle Sensor

Actuator
Best performance for VTG adjustment to optimize Sealed module integrating various keyless access
functional application and reduce fuel consumption. functions into a door handle or exterior module.
S&A
› Continuous adjustment of external application › Easy integration of various sensors / functions for
Benefits
Benefits
using rotating output shaft Keyless Entry System in a single sealed module
› Ideal for use in VTG applications › Communication to system: Current modulation,
voltage output, LIN, CAN, etc.
› Permanent feedback signal (non-contacting)
› Options: Default position, integrated electronic › Power consumption: ~70 µA for double zone sensor
Techical Information
› Response time: 5 ms up to 30 ms
› Max. external load
without return function: 40 Ncm › Detection distance ~2 mm to 20 mm, depending

(lock / unlock ) : on door handle type
› Max. continuous holding torque without
return function at 140°C: 65 Ncm › Antenna inductance: From 100 µH up to 500 µH
› Response time: < 150 ms at 120°C › Temperature range: – 40°C up to + 85°C
› Operation temperature: – 40°C up to +140°C › Integrated pocket and ground light output
S & A – Sensors 138 139
Easy Trunk Access Sensor Electrostatic Particulate

Matter Sensor
Sealed capacitive sensor module integrated inside Sensor for on-board

a bumper for keyless access to the trunk or sliding doors diagnosis of diesel particulate filters.
S&A
› Trunk/sliding door easy hands-free opening / closing › Continuous output signal for DPF diagnosis
Benefits
Benefits
› Sensor activated with movement of leg (no need to › Lowcross-sensitivity to noise factors
press a button or remote control)
› Signal available down to low concentrations
› Integration of capacitive sensor inside a bumper
› Environmental robustness by design (no measuring
› Dual electrode set to prevent false activations ceramic)
› Detection distance: Up to 15 cm (tunable to › Diagnosis functions compliant with latest OBD

application) regulations
› Quiescent current : 2.5 mA (no low power mode), › Measuring range: 0 mg/m³ up to 50 mg/m³
250 μA (low power mode)
› Repeatability +/– 10% of sensor signal
› Temperature range: – 40°C up to + 85°C (reference bench): above 5 mg/m³
› LIN, ON / OFF voltage or current output › Gas temperature: Up to 950°C
› Vehicle integration guidelines available for specific › Data link: CAN 2.0 or SAE-J-1939
configurations (trailer hitch, US radars, etc.)
› Mechanical interface: M22x1.5 (spinning nut )
S & A – Sensors 140 141
Fluid Sensor Fluid Sensor

Biodiesel Flex Fuel Ethanol
Detection of biodiesel content in diesel fuel. Detects ethanol concentration

in gasoline / ethanol fuel mixture.
S&A
› Designed to accurately compensate for differences › Highly accurate prediction of ethanol concentration
Benefits
Benefits
in worldwide biodiesel feed stocks
› Enables ethanol detection before injection /
› Outputs biodiesel concentration and fuel combustion
temperature within 500 ms after start up
› Outputs ethanol concentration and fuel temperature
› Self diagnostic capability, supports OBD-II within 250 ms after start-up
› Self diagnostic capability
› Measurement principle:
Capacitive-based on Flex Fuel Technology

› Measurement principle:
› Accuracy: +/– 5 % ( Americas and Europe) Capacitive (0% up to 100 % ethanol content)
+/– 7% ( Worldwide feed stocks)
› Accuracy: +/– 5 % ethanol concentration
› Pressure range: < 10 bar
› Pressure range: < 10 bar (145 psi)
› Fuel temp. range: – 40°C up to +125°C
› Fuel temp. range: – 40°C up to + 90°C
› Environmental temp.: – 40°C up to +125°C
› Environmental temp.: – 40°C up to +150°C
S & A – Sensors 142 143
Fluid Sensor – Oil Level Fluid Sensor

Passive Electrothermic Oil Level Switch
Sensor monitors correct engine oil level to avoid overfill or Level switch to monitor engine oil level below minimum
underfill during driving or at key-on. threshold.
S&A
› Overfill and low level indication › Low oil level detection
Benefits
Benefits
› Absolute measurement of oil level in static and › Different connectors possible
dynamic conditions
› Simple on / off output
› Replacement of oil dipstick
› Market proven
› Different mounting positions
› Measuring principle: Magnetic reed switch
› Temperature measurement optional
› Different switch heights possible
› Measuring principle: Thermo resistive heated wire
› Normally on (switch closed)

› Measuring range: 100 mm between min. and max.
› Tolerance: +/–1 mm
› Accuracy approx.: +/–3 mm
› First measurement : Available 0.6 s after key-on
› Measuring interval: > 10 s
› Operating temp.: – 40°C up to +160°C
S & A – Sensors 144 145
Fluid Sensor – Oil Level Fluid Sensor – Urea

Ultrasonic Concentration and Level
Best price-performance ratio sensor to monitor correct Urea Concentration and Level Sensor helps to fulfill emis-
engine oil level. sion legislation and OBD requirements for SCR systems.
S&A
› Replacement of oil dipstick › Fast and accurate measurement of urea
Benefits
Benefits
› Detection of low level and overfill concentration (AdBlue®/ DEF) in the SCR system
› Absolute measurement of oil level static /dynamic › Additional measurement of urea level and
temperature
› Low power consumption
› Flexible mounting positions
› Temperature measurement optional
(in-tank, in-extraction unit, in-line)
› Measuring principle: Ultrasonic echo › Proven sensor technology
› Measuring range: 18 mm up to 150 mm Technical Information › Measuring principle: Ultrasonic

› Accuracy: +/–2 mm
› Output signal: PWM / CAN / SENT
› Operating temperature: –10°C up to +150°C (level)
– 40°C up to +150°C (temp.) › Measuring range:
– Concentration: 0 % up to 50 % urea mass
› First measurement : Available after 0.4 sec.
above freezing point
› Measuring interval: 1 sec. – Level: 20 mm up to 500 mm
› Interface: PWM › Measuring interval: 1 sec.
S & A – Sensors 146 147
In Cylinder Pressure Sensor Knock Sensor –

M6
Real-time combustion sensing, providing in-cylinder Measures structural vibrations in internal combustion
combustion pressure information. engine to continuously adjust ignition parameters.
S&A
› Tolerance compensation (injection, airpath, engine, › Optimization of ignition timing for max. efficiency
Benefits
Benefits
fuel, etc.) : Combustion stability control
› High sensitivity
› System cost improvement : Intake /exhaust models
› Small design with M6 bolt for space and weight
› Airpath accuracy and dynamic control savings
› Enables alternative combustion control (HCCI) › Increased engine power, decreased fuel consumption
› Embedded electronic using direct analog path – › Fits for automotive, two wheelers and others
no time delay
Technical Information › Acceleration sensor based on piezo ceramic
› Independent of glow plug, improved robustness technology with a range of: 0 g up to 400 g
and signal
› Frequency range: 3 kHz up to 25 kHz
› Large bandwidth suitable for diesel and gasoline
› Possible integration of discharge resistor
› Output signal: 0 V up to 5 V (ratiometric)
› Glue and nut designs available
› Measurement range: 0 bar up to 200 bar
› Compatible with current ECU designs
S & A – Sensors 148 149
Knock Sensor – Wide Band Mass Airflow Sensor

FMT MAF SENT
Measures structural vibrations in the combustion engine Measurement of the intake

to continuously adjust ignition parameters. airflow for the engine management system.
S&A
› Optimized ignition timing for maximum efficiency › High flow measurement accuracy and signal stability
Benefits
Benefits
› High sensitivity › Integral protection against water and contamination

› Compact design, nested bolt possible › Excellent performance with intake airflow pulsation
› Increase engine power › Enhanced EMC performance
› Decrease fuel consumption › Options for humidity and pressure sensors
› Acceleration sensor based on piezo ceramic › Sensing technology: Next generation MEMS
technology Technical Information

› Flow range: 4.5 kg / h up to 900 kg / h
› Frequency range: 3 kHz up to 25 kHz (62 mm tube)
› Possible integration of discharge resistor › New-part tolerance: 1.3 %
› Integrated connector or cable version › Supply voltage: 5 V +/– 0.5 V
› Glue and nut designs available › Supply current : 5 mA maximum
› Output signal: SENT V4
S & A – Sensors 150 151
Mass Airflow Sensor Mass Airflow Sensor

FMT MAF + HPT SENT MT
Measurement of the intake airflow humidity, pressure and Measurement of the intake airflow for the engine
temperature for the engine management system. management system.
S&A
› High flow measurement accuracy › High flow measurement accuracy and signal stability
Benefits
Benefits
› Integral protection against water and contamination › Integral protection against water and contamination
› Excellent performance with intake airflow pulsation › Excellent performance with intake airflow pulsation
› Enhanced EMC performance › Customer specific programmable output
characteristic
› Options for humidity and pressure sensors
› Sensing technology: Hot-film bi-directional MEMS
› Sensing technology: Next generation MEMS
› Flow range: 5 kg / h up to 800 kg / h

› Flow range: 4.5 kg / h up to 900 kg / h (62 mm tube)
(62 mm tube)
› New-part tolerance: 1.5 %
› New-part tolerance: 1.3 %
› Supply voltage: 5 V +/– 0.5 V
› Supply current: 8 mA maximum
› Output signal: SENT V4
› Output signal: Frequency or SENT digital
› Intake air temperature sensor optional
S & A – Sensors 152 153
Near Field Communication Position Sensor

External Reader Linear Contactless
Hall Effect
Technology
Sealed module integrating in it and multi zone capacitive Sensor mainly used for gear neutral and all gear sensor,
sensor into a door handle or exterior module. clutch master cylinder, pedal, fork position sensor.
S&A
› Enables car access with smart phone and › Small sensor size
Benefits
Benefits
information download / configuration upload

› Through aluminum wall measurement
› Enables smart car sharing and remote access
› High air-gap
› Easy integration of various functions for Keyless
› Compatible with Ferrite Magnets
Entry System: NFC reader and capacitive lock /unlock
› Fully sealed module; Smart door handle integration › Overall accuracy: Min. +/–2 %
› Target : Magnet
› NFC protocols ISO / IEC 14443a, ISO / IEC 18092:2013
› Measurement : Linear up to 60 mm
› NFC range: ~40 mm, depend. on door handle type
› Air gap: Up to 11 mm
› Dark current : 240 uA for NFC, 70 uA for dual zone
capacitive sensor › Operating temp. range: – 40°C up to +150°C
› Temp. range: – 40°C up to + 85°C › Operating voltage: 5 V +/– 0.5 V
› Communication to system: › Output signal: Analog, PWM, SPI or SENT
Current modulation, voltage output, LIN, CAN, etc.
› X-Y measurement possible
S & A – Sensors 154 155
Position Sensor Position Sensor

Linear Contactless Rotary Contactless
Inductive Inductive
Technology Technology
Sensor mainly used for Park / No park, CMC, Sensor used for PRND, rotary valve position (EGR, ETC,
linear actuators, PRND, fork position sensor. ACV, water valve, etc.), general purpose rotary actuators.
S&A
› Metallic target (Al, Fe, etc.), no magnet needed › Metallic target, no magnet
Benefits
Benefits
› Immune versus low frequency magnetic field › Immune to low frequency magnetic field,
(electric motor, starter current, etc.), no pollution by no pollution by iron particles
iron particles › Single or redundant configuration
› Single or redundant output › ASIC available
› Measuring range: 6 mm up to 60 mm
› Measuring range: Up to 360°
› Overall accuracy: +/–2 % › Overall accuracy: +/– 1%
› Air gap: Up to 5 mm › Air gap: Up to 5 mm
› Linearity: < +/–1% full scale › Linearity: < +/–1% full scale
› Operating temperature range: – 40°C up to +160°C › No hysteresis
› No hysteresis › Operating temperature range: – 40°C up to +160°C
› Output signal: Analog, PWM or SENT › Output signal: Analog, PWM or SENT
› Flat or cylindrical shape targets › End of shaft or off axis configuration
S & A – Sensors 156 157
Pressure Sensor Pressure Sensor

Brake Booster Absolute Brake Booster Gauge
Pressure measurement for Start-Stop applications. Direct measurement of vacuum inside brake booster.
S&A
› Flexible calibration of transfer functions › Flexible calibration of transfer functions
Benefits
Benefits
› Precision programmable clip levels › Precision programmable clip levels
› Internal and output diagnostic capability › Internal and output diagnostic capability
› High accuracy and temperature stability › High accuracy and temperature stability
› Fulfills toughest EMC requirements › Flexible housing, connector, and mounting designs
› Pressure range: 10 kPa up to 120 kPa › Pressure range: –105 kPa up to 40 kPa (gauge)
› Accuracy: 1% full scale (10°C up to 85°C) Technical Information

› Accuracy: 1% full scale (10°C up to 85°C)
› Temperature range: – 40°C up to +140°C › Temperature range: – 40°C up to +125°C
› Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V
› Supply current at 5 V: 10 mA maximum › Supply current at 5 V: 10 mA maximum
› Output signal: Analog or SENT › Load resistance: > 4.7 kOhms
› Output signal: Analog or SENT
S & A – Sensors 158 159

Filter Control Gauge High Pressure Diesel
Relative measurement of pressure downstream of air filter. Direct measurement of pressure in diesel fuel rail.
S&A
› Flexible calibration of transfer functions › High accuracy and temperature stability
Benefits
Benefits
› Precision programmable clip levels › High vibration robustness (low / high frequencies)
› Internal and output diagnostic capability › Modular design for connector and mounting
› High accuracy and temperature stability
› Flexible calibration of transfer functions
› Fulfills toughest EMC requirements
› Internal and output diagnostic capability
› Flexible housing, connector, and mounting design
› Pressure range: 0 bar up to 2,500 bar
› Adjustable characteristic via electronic calibration
› Pressure range: 0 kPa up to 10 kPa › Temperature range: – 40°C up to +140°C

› Operating temp.: – 40°C up to +125°C › Supply: 5 V, 10 mA
› Supply voltage: 5 V +/– 0.25 V › Output signal: Analog or SENT
› Output signal: Analog or SENT › Accuracy: 0.5 % full scale output
› Transfer function: Linear, ratiometric (analog version)
› Response time: < 1 ms
› Accuracy over
full-scale: 3% full span (10°C up to 85°C)
S & A – Sensors 160 161

High Pressure Gasoline Manifold Absolute
MAP
TMAP
BAP
Direct measurement of pressure in gasoline fuel rail. Direct measurement of pressure in manifold.
S&A
› High accuracy and temperature stability › Flexible calibration of transfer functions
Benefits
Benefits
› High vibration robustness (low / high frequencies) › High accuracy and temperature stability
› Modular design for connector and mounting › Low cost design and high quality
› Flexible calibration of transfer functions › Fulfills toughest EMC requirements
› Internal and output diagnostic capability › Flexible housing, connector, and mounting design
› Pressure range: 0 bar up to 500 bar › Pressure range: 40 kPa up to 120 kPa (for BAP)
› Temperature range: – 40°C up to +140°C › Pressure range: 7 kPa up to 500 kPa
(for MAP and Turbo MAP)
› Supply: 5 V, 10 mA
› Accuracy: 0.5 % full scale output
› Response time: < 1 ms
S & A – Sensors 162 163
Pressure Sensor – Manifold Pressure Sensor

Absolute and Temperature Manifold Gauge
MAP with integrated temperature sensor directly Relative measurement of pressure or vacuum in the
measures the pressure and temperature in the manifold. intake manifold.
S&A
› Flexible calibration of transfer functions › Flexible calibration of transfer functions
Benefits
Benefits
› High accuracy and temperature stability › Precision programmable clip levels
› Low cost design and high quality › Internal and output diagnostic capability
› Fulfills toughest EMC requirements › High accuracy and temperature stability
› Flexible housing, connector, and mounting design › Fulfills toughest EMC requirements
› Pressure range: 40 kPa up to 120 kPa (for TBAP) › Pressure range: –105 kPa up to 40 kPa (gauge)
› Pressure range: 7 kPa up to 500 kPa › Accuracy: 1% full scale (10°C up to 85°C)
(for TMAP and Turbo TMAP)
› Supply current at 5 V: 10 mA maximum
› Load resistance: > 4.7 kOhms
S & A – Sensors 164 165
Pressure Sensor – Particle Pressure Sensor – Particle

Filter Differential (2 Ports) Filter Gauge (Single Port)
Differential pressure measurement across a diesel Relative measurement of exhaust pressure before
particulate filter or low pressure EGR system. or after the DPF.
S&A
› Direct measurement of pressure › Flexible calibration of transfer functions
Benefits
Benefits
› Flexible calibration of transfer functions › Precision programmable clip levels
› Precision programmable clip levels › Internal and output diagnostic capability
› Internal and output diagnostic capability › High accuracy and temperature stability
› High accuracy and temperature stability
› Pressure range: 0 kPa up to 100 kPa
› Pressure range: 0 kPa up to 125 kPa

– P1 (downstream port ) : 0 kPa up to 50 kPa
– P2 (upstream port ) : 0 kPa up to 150 kPa › Accuracy: 1% full scale (10°C up to 85°C)
› Supply voltage: 5V › Temperature range: – 40°C up to +125°C
› Operating voltage: Programmable › Supply voltage (Vs): 5 V +/– 0.5 V
(0.2 V up to 4,800 V)
› Output signal: Analog
› Accuracy: 0.8 % FSS (0°C up to 70°C) › Load resistance: > 4.7 kOhms
› Temperature range: – 40°C up to +125°C › Response time: < 2 ms
S & A – Sensors 166 167
Pressure Sensor Smart NOX Sensor

Secondary Air Absolute
Direct measurement of pressure in secondary air flow. NOX measurement, upstream

or downstream SCR. Optimizes urea injection.
S&A
› Flexible calibration of transfer functions › Real time high accuracy measurement
Benefits
Benefits
› High accuracy and temperature stability › Sensor performance independent of catalyst
or ECU supplier and engine management system
› Low cost design and high quality
› Modular “Stand-alone” NOX sensor enabling
EU / US / Japan emission standards compliancy
› Flexible housing, connector, and mounting design
› Measuring principle: ZrO2-based multilayer sensor
› Pressure range: 50 kPa up to 150 kPa (for SAA) with integrated heater and 3 oxygen pumps
› Accuracy: 1% full scale (10°C up to 85°C) › Triple output signal NOX , binary λ, linear λ
or O2-concentration
› Supply voltage: 12 V or 24 V
› Data link: CAN 2.0 or SAE-J-1939
› Operating gas temp.: 100°C up to 800°C
› Load resistance: > 4.7 kOhms
S & A – Sensors 168 169
Smart Position Sensor Temperature Sensor

Cover Coolant / Fuel / Oil
Smart Position Sensor used for controlling Temperature measurement in several liquid media
General Purpose Electrical Actuators. (coolant water, oil, fuel).
S&A

› Inductive position sensor with ASIC › Clip or screw-in design
Benefits
Benefits
› Immune to low frequency magnetic fields › Wide range of applications
(metal target, no magnet )
› High accuracy
› H-bridge driver for DC motor (ASIC)
› Short response time
› Microcontroller for position control
› High temperature operation › Long-term stability
› Sensor measuring range: Up to 360° › Oil, water, fuel, temperature measurement

– Engine coolant: – 40°C up to +140°C

› Sensor accuracy: +/–1%, no hysteresis
– Engine oil: – 40°C up to +150°C
› End of shaft or off axis sensor configuration – Fuel: – 40°C up to +140°C
› H-bridge driver with 4 Amp current capability › Accuracy: +/–1°C (at 0°C)
› 16-bit MCU with embedded PID control
› Response time: Up to 3 s
› Operating temperature: Up to 140°C
› Built in protections: O/L, O/T, O/V, U/V CAN,
LIN or PWM interface
S & A – Sensors 170 171
Temperature Sensor Temperature Sensor

EGR High Multiple
Temperature measurement in EGR system, EGR bypass Temperature acquisition for closed loop aftertreatment
valve function diagnostic and thermal protection. control (DPF, SCR. DeNOX / LNT).
S&A
› Temperature measurement of EGR systems › Smart sensor with digital output, high accuracy
Benefits
Benefits
› Connector design for EGR temperatures › System price benefit
up to 450°C
› Stable signal over lifetime
› Resistant to exhaust gases and other relevant
› Proven high temperature robustness
chemicals at EGR applications
› Fast response due to small thermal inertia
› Robust stainless steel cup
› Thermocouple sensor technology, Type N
› RTD or NTC sensor technology
› Response time: 7 s at 10 m / s flow (4 s at 20 m / s)

› Different Pt curves possible (Pt200, Pt1000)
› Sensing temp.: – 40°C up to +1,000°C
› Measuring tolerance: +/–7°C over lifetime
› Working temp.
› Response time (T63 ) : < 13 sec. at air speed 10 m/s
electronics: –40°C up to +140°C
› Temperature range: – 40°C up to + 450°C;
› Accuracy: < 500°C +/– 5°C over lifetime
up to + 600 °C (peak 60 sec.)
> 500°C +/–1% over lifetime
S & A – Sensors 172 173
Temperature Sensor Powertrain Drivetrain

High Single Efficiency Solutions
Sensor with proven high temperature robustness

turbocharger protection.
› Smart sensor with digital output, high accuracy

Benefits
› System price benefit

› Stable signal over lifetime
› Fast response due to small thermal inertia
› Sensing technology: Thermocouple

› Response time: 8 sec. at 10 m /s flow

(6 sec. at 20 m/s)
› Temperature range:
in production (diesel) – 40°C up to + 900°C
in development – 40°C up to +1150°C
› Working temp. electron.: –40°C up to +145°C
› Accuracy: – 40°C up to + 500°C: +/– 5°C
> 500°C: +/–1%
› Output: SENT Interface
FEM – Fuel & Exhaust Management 174 175
Fuel & Exhaust

Management
Fuel Delivery Module Fuel Delivery Module

for Standard Applications for High-End Applications
In-tank Fuel Delivery Module for gasoline and diesel with

the opportunity to integrate various functions.
› Cost effective modular design to cover various › Developed for high performance
Benefits
Benefits
customer requirements vehicles
FEM
› Constant flow or demand regulated › Applicable for complex tank geometries
› Multiple jet-pump and fuel level sensor solutions
› Brushless EC pumps or brushed-type DC pumps
› Dual pump configurations

› Optional integrated: Fuel level sensor, filter, pressure
regulator, electronics, vent valves and tank leakage
› Brushless EC pumps or brushed-type DC pumps
detection sensor
› Hydraulic performance: > 280 l / h at 6.5 bar
Fuel Delivery Module Fuel Level Sensor with

for Entry Level Vehicles a Sealed Contact System
MAPPS (MAgnetic
Passive Position
Sensor)
Fuel Level Sensor with a

fully capsulated sensor element.
› Very cost effective solution due to high flange › Hermetically sealed contacts assure robust
Benefits
Benefits
integration protection against corrosion
FEM
› Suitable for compact tanks with low flow › Longer life time (>10 million cycles) because of a
requirements wear free measurement system
› Also applicable for two-wheelers and recreational › Electromagnetic compatibility
vehicles
› Measuring range: Up to 90°
› Low module weight
› Operating current : Up to 20 mA
› Integrated vent valve
› Resolution: 1.7 degree / pad
› Serviceable elements
› Max. resistor tolerance: +/–1%
Fuel Level Sensor with an Electric Fuel Pump – EC

Open Contact System
Bracket with
Three Finger
Contacts
Gasoline Pump Diesel Pump
Cost effective sensor In-tank fuel pump with

with open contact system. brushless electronically commutated (EC) motor.
› Redundant contacts › Improved quality, reliability and durability (less parts,

Benefits
Benefits
no commutation wear)
› Various contact materials for different technical
FEM
requirements and market specific fuel compositions › Higher efficiency
› Electromagnetic compatibilty
› Measuring range: Angle up to 100°
› Body born noise reduction

› Operating current : 1 up to 20 mA
› Resolution: 1.25 degree /pad › Gerotor and turbine pump principles
› Max. resistor tolerance: +/–1% Technical Information › Pressure: Up to 700 kPa
› Operating temperature: – 40°C up to + 80°C › Flow, typ.: 330 l / h at 500 kPa
› Efficiency, typ.: 35 %
› Size: 38 mm, 43 mm, 50 mm
› Media: Gasoline (up to E100),
diesel (incl. RME )
Electric Fuel Pump – DC Fuel Delivery Controller
Gasoline Pump Diesel Pump
In-tank fuel pump with brush-type direct current motor. Electronics for demand
regulation of fuel delivery modules.
› Most cost-effective solution for non-electronically › Reduced consumption of electrical energy

Benefits
Benefits
regulated systems
› Enhanced lifetime
FEM
› Stand-alone (electronics not required)
› Reduced vibration and noise level
› Gerotor and turbine pump principles
› Stand-alone device or integrated in fuel module
› Pressure: Up to 700 kPa
› Operating voltage: 6 V up to 16 V
› Flow, typ.: 230 l / h at 500 kPa
› Electrical power: 100 W up to 200 W
› Efficiency, typ.: 30 %
› Size: 28 mm, 38 mm, 43 mm
› Control input / output signal: PWM
› Media: Gasoline (up to E100),
› Degree of protection: IP6K7 and IP44
diesel (incl. RME )
› Weight: Approx. 130 g and up
Tank Domain Controller Flat Channel METALIT®

(Standard Structure)
Electronics for demand Metal substrate

regulation of fuel delivery modules. for catalytic converter.
› Reduced consumption of electrical energy › Larger surface area than ceramic substrates
Benefits
Benefits
› Enhanced lifetime › Improved cold-start performance
FEM
› Reduced vibration and noise level › Lower backpressure
› Processing of other signals (e.g. fuel level sensor, › Smaller package space
pressure sensor, leakage detection)
› Combustion engine exhaust emission control
› Operating voltage: 6 V up to 16 V
› Three-way catalyst for gasoline engines

› Electrical power: 100 W up to 200 W
› Cell density: 50 cpsi up to 1600 cpsi
› Foil thickness: 25 μm up to 110 μm
› Control input / output signal: CAN (1.0 mil up to 4.3 mil)
› Degree of protection: IP6K7 and IP44
› Weight : Approx. 130 g and up
CS-Design LS-Design®
(Crossversal Structure) (Longitudinal Structure)
New metallic substrate design to increase efficiency Metal substrate

without penalty in back pressure. for catalytic converter.
› Skew corrugated foils without flat foil layer › Increased efficiency compared to flat channel
Benefits
Benefits
structure
› Elimination of flat foil layer
FEM
› Turbulence generating secondary corrugation
› Weight and cost saving
› Less material, improved light-off-performance
› GSA compensation by improved mass transfer
› Backpressure and package advantage
› Backpressure advantage against standard catalysts
› Cost advantage
Technical Information › Combustion engine exhaust emission control

› DOC, NOX-adsorber and SCR catalyst for
diesel engines › DOC, NOX-adsorber and SCR catalyst for
diesel engines
› Variance of cell densities and foil thicknesses
› Cell density: 100 /200 cpsi up to 400/800 cpsi
› Foil thickness: 40 μm up to 80 μm
(1.6 mil up to 3.2 mil)
PE-Design® LS-Design® and PE-Design®

(Perforated Structure)
Metal substrate Metal substrate

for catalytic converter. for catalytic converter.
› Perforation results in light weight › Corrugated layer in LS-Design®

Benefits
Benefits
› Less material, improved light-off performance › Flat layer in PE-Design®
FEM
› Low backpressure, flow homogenization › Internal flow homogenization
› Improvement in case of inhomogeneities › Turbulence generating secondary corrugation
› Flow- and / or concentration improvement › Performance and utilization improvement
› Combustion engine exhaust emission control › Combustion engine exhaust emission control
› Three-way catalyst for gasoline engines › Three-way catalyst for gasoline engines
› NOX-adsorber for diesel engines › DOC and SCR catalyst for diesel engines
› Cell density: 100 /200 cpsi up to 400/800 cpsi › Cell density: 100 /200 cpsi up to 400/800 cpsi
› Foil thickness: 40 µm up to 80 µm › Foil thickness: 40 µm up to 80 µm
(1.6 mil up to 3.2 mil) (1.6 mil up to 3.2 mil)
TS-Design® PM-METALIT®
(Transversal Structure) (Particulate Matter Filter)
Metal substrate Metal diesel

for catalytic converter. particulate matter filter.
› Increased efficiency compared to flat channels › Passive soot regeneration by NO2 from DOC
Benefits
Benefits
› Less material and costs for same efficiency › Active regeneration by engine measures possible
FEM
› Backpressure advantage › Regeneration in wide operating temperature window
› Smaller package space › Maintenance-free with appropriate engine fuel
and oil
› Installation in cars and light duty vehicles

› Highest milage in heavy duty trucks and buses
› DOC, NOX-adsorber and SCR catalyst for
diesel engines › Offroad proven
› Cell density: 100 cpsi up to 500 cpsi › Multiple serial applications and retrofit since 2004
› Foil thickness: 40 µm up to 110 µm › Optimized operation in combination with DOC
(1.6 mil up to 4.3 mil) in LS-Design®
› EU / China IV/ V, Tier 4i / f and similar regulations
MX-Design® Mantle-less
(Mixing Structure) Metallic Substrate
Metal substrate Mantle-less

for catalytic converter. metallic substrate.
› Catch of AdBlue® droplets on coated surface › Robust and proven metallic substrate technology
Benefits
Benefits
› Enables significantly increased Adblue® injection › Lowest weight
FEM
› Low load / operation improvement for SCR › Adjusted canning to prevent heat release
› Improves urea conversion to ammonia for SCR › Designed for high-volume, fully automatic
production process
› Reduced risk of deposits formation downstream
› Metal substrates can be coated with various catalyst
formulations for combustion engine exhaust

› Hydrolysis catalyst for diesel engines emission control
› Evaporator and catalyst together › Application as three-way catalyst for gasoline
engines
› Low cell density shovel system
› Available in a variety of dimensions; Well-suited for
› Combined with perforated flat foil
motorcycle applications
› Cell density: 40 cpsi
› Foil thickness: 65 μm
Exhaust Gas Recirculation EMICAT®

Filter Electrically Heated Catalyst
Lifetime EGR-filter with highest efficiency to protect turbo- Electrically heated

charger from ceramic particles due to DPF regeneration. catalyst including a high effective support catalyst.
› Optimum engine dynamics › Catalyst light off temperature reached in less time
Benefits
Benefits
› Component protection for exhaust gas turbocharger › Reduced catalyst cooling during no-load phases
FEM
and engine › Potential for precious metal reduction
› Utilization for DPF OBD › Additional energy supports vaporization of liquids
› Replacement for soot-sensor › Improved low-temperature SCR
› Intelligent activation for lower heating power
› Usage of high efficient 2-layer TELA-wire mesh
› Evolvent weaving structure (GKD) › Use of recuperation energy

› Support of RDE challenges
› Optimized filter efficiency
› Operation voltage: 12 V/ 24 V/48 V
› High mechanical durability
› Power at 12 V: 300 W up to 3,600 W
› Power at 24 V: 1,000 W up to 7,200 W
› Power at 48 V: 500 W up to 4,000 W
› Diameter: 50 mm up to 264 mm
Controller for Electrically Modular Diesel Engine

Heated Catalyst (EMICAT®) System
Power control for the electrically heated catalyst Diesel oxidation catalyst / NOX storage catalyst substrate
(EMICAT®), based on a 32 bit microcontroller unit. for lowest emission diesel cars.
› Communication with ECU and SCR controller via CAN › Lowest emissions due to fast light-off in
Benefits
Benefits
› Diagnostic and development tools via CAN closed-coupled position
FEM
› Electrically protected output › Better temperature control for DOC and NSC during
DPF regeneration
› EMC compatible design
› Cost effective by utillizing same substrate and
› Redundancy switch canning parts
› Voltage: 12 V (48 V in development )
› Optimum package usage

› Electrical power: 1 kW › High perfomance metal substrate with LS-Design®
› Max. continuous current: 100 A › Catalyst integrated temperature sensor (SensorKat™)
› PWM output, 10 Hz base frequency › Closed-coupled position directly at turbocharger
› Molex MX 150 communication connector outlet
› M6 power connectors, IP6K9K
› Dimensions incl. flanges: 120 x 100 x 34 mm
› Ambient temperature: – 40°C up to +120°C
Closed-Coupled Exhaust After- Closed-Coupled Exhaust

treatment System Gasoline Aftertreatment System Diesel
Three-way catalyst substrate for Oxidation catalyst substrate

lowest emission gasoline cars. for lowest emission diesel cars.
› Closed-coupled position, fast light-off › Closed-coupled position, fast light-off

Benefits
Benefits
› Lowest catalyst material enabled by LS-Design® › Lowest catalyst material enabled by LS-Design®
FEM
› CompactCat canning › CompactCat canning
› Optimum exhaust gas temperature utilization › Optimum exhaust gas temperature utilization
› Same substrate and canning parts for gasoline
› Same substrate and canning parts for gasoline
and diesel
and diesel
› High-performance metal substrate with LS-Design®
Technical Information › High-performance metal substrate with LS-Design®

› Catalyst-integrated lambda-sensor
(Lambdasondenkat™) › Optimum flow distribution to directly connected DPF
› Optimized engine control response and accuracy › CompactCat : Hot gas circulating the catalyst
surfaces
› CompactCat : Hot gas circulating the catalyst
surfaces › Closed-coupled position directly at turbocharger
› Closed-coupled position directly at turbocharger outlet
outlet
Compact SCR EHC System Air-assisted

Urea Dosing Unit UDA
Oxidation catalyst in combination with electrically heated Air assisted AdBlue® (DEF) metering pump unit in combi-
catalyst and reverse AdBlue® injection. nation with a passive working two-phase nozzle
› Closed-coupled position, fast light-off › Robust and proven frame mounted pump unit
Benefits
Benefits
› Lowest catalyst material enabled by LS-Design® › Low consumption of compressed air
FEM
› CompactCat canning › Fine spray quality due to air-atomization of urea
› Reverse AdBlue® injection on heating disc › Designed for heavy duty trucks, NRMM and retrofit
› NH3 formation at lowest temperatures with › Injection into high pressure exhaust (pre-turbo)
EMICAT® support
› Pump Capacity: 7.5 l / h
› High-performance metal substrate with LS-Design® Technical Information
› Operating pressure: nominal 3 bar up to 6 bar

› CompactCat : Hot gas circulating the catalyst
› Integrated electronic control
surfaces
› Master, slave and stand alone modes
› Closed-coupled position directly at turbocharger
outlet › Compressed air control and mixing inside
› Electrical heated catalyst (EMICAT®) › Precise urea metering by membrane pump
for 12 V up to 48 V/ 0.3 kW up to 7.2 kW
SCR Catalyst Powertrain Exhaust

Aftertreatment Solutions
NOX emission reduction on high efficient catalyst surface

using ammonia formed out of injected AdBlue® (DEF).
› Turbulence generating structures

Benefits
› Reduced volume, lower space requirements

› Low backpressure for optimum fuel consumption
› Applicable for cars, trucks and Non-Road Mobile
Machinery (NRMM)
› Wide variety of round and non-round geometries

available
› Serial production diameter up to 450 mm
› Cell density and foil structure optimized to
application
Continental Automotive GmbH
Powertrain Division
Siemensstrasse 12
93055 Regensburg · Germany
Phone + 49 941 790 - 0
www.continental-automotive.com
Legal notice
The information provided in this brochure con-
tains 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 infor-
mation is not meant or intended to be a special
guarantee for a particular quality or particular
durability. An obligation to provide the respec-
tive characteristics shall only exist if expressly
Printed in Germany · 09 / 2015 · EN · 5.0 k · Order no.: 46-03-0103EN

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 2 3

If everyone drives a car, Content

31 ES – Engine Systems 61 SYN – Synerject

91 TR – Transmission 120 S & A – Sensors & Actuators

1 Engine Control Unit 13 Fuel Rail

Gasoline Port Fuel Injection

1 Canister Purge Solenoid 9 Manifold Absolute Pressure Sensor

Diesel Injection and

EMS3 Engine Management ECU Gasoline

› Up to 6 cores and 16 MB flash size › Core: Monaco /Andorra, 80 MHz

ECU Gasoline Port Fuel ECU Gasoline

› Flash size: 2.5 MB up to 16 MB

› Connector pins: 96 or 128 › Connector pins: 336

› Housing temp. range: – 40°C up to + 105°C › ISO26262, AUTOSAR 4.2

ECU Gasoline SDI ECU Bi-Fuel

› Core: Monaco, 80 MHz

ECU Gasoline SDI and TCU ECU Diesel

TMS: TC1724 80 MHz › Flash size: 2.5 MB up to 8 MB

ECU Diesel PCR ECU Diesel PCR

› Core: Monaco / Andorra › Core: TC1767

› Flash size: Up to 4 MB › Flash size: 2 MB

ECU Diesel Platform ECU Diesel

› Supports CNG injection systems › Fulfills current emission requirements

› Tightness: IP6K9K › Tightness: IP69K, IP67

› Connector pins: 154 › Connector pins: 141

ECU Aftertreatment Control Glow Plug Control

› 12 V/ 24 V supply › Glow plug PWM control with electrical diagnosis

› Flash size: 4 MB › Core: Bolero, 32 MHz

Selective Catalytic Reduction Connected Energy Manager

› Flash size: 1 MB › Core: Tricore multicore architecture

Gasoline High Pressure Pump Diesel High Pressure Pump

› Digital Inlet Valve (DIV) technology › Pressure: Up to 2,500 bar

Diesel High Pressure Pump Diesel High Pressure Pump

› Displacement : 0.58 ccm / revolution › Pressure: Up to 2,500 bar

Gasoline DI XL3.1 Gasoline DI XL5

› Minimum dynamic flow: 1.5 mg /stroke at 200 bar

Gasoline Deka 7/9 Gasoline Deka 10 Port

Diesel Piezo Common Rail Diesel Piezo Common Rail

› Pressure: Up to 2,500 bar

Diesel Fuel Rail Gasoline

› GDI: Fuel rail assembly up to 350 bar

LPG Liquefied Air Cooled SCR Injector

› Sauter Mean Diameter (SMD): 70 μm up to 130 μm

Liquid Cooled SCR Injector Diesel Dosing

biodiesel and increased engine durability

Gasoline Turbocharger Gasoline Turbocharger

thermodynamics, drivability and best fuel economy

Synerject M3A Air Module

› ABV, TPS and TMAP sensor integrated

M3B Air Module Engine M3C Engine Control Unit

› 256 KB ROM (flash), 16 KB RAM

M3D Ride by Wire Customized

› From 24 pins up to 144 pins, automotive connector

› 896 KB ROM (flash), 2 KB E2PROM and 32 KB RAM › Plastic or aluminum housing

› Separate safety monitoring unit for ETC system › Configurable I / Os:

Mechanical Throttle Body Customized Electronic

› Minimum idle flow at 40 kPa ∆P: 2 kg / h

› Vibration level: 30 g › Response time of single throttle: < 90 ms (at 25°C)

Strata Air Injector Electronic Oil Pump

› Electromechanical valve › Fully flexible mounting location

› Control of flow by Pulse-Width Modulation

› Validated automotive components

Ignition Coil Oxygen Sensor