Continental launches a series of new technologies to meet the trend of vehicle electrification

    Adding electrical components to the drivetrain makes a car's internal combustion engine more efficient, and the effect is more obvious than just making minor adjustments to the engine. It reduces CO2 emissions and fuel consumption, which is a benefit that drivers can directly experience, which is why fuel-saving 12-volt stop-start systems are so successful. These systems represent the entry level of electric vehicles. Of course, the higher the degree of electrification, the greater the efficiency improvement. However, the market penetration is somewhat different from this expectation. José Avila, President and Member of the Executive Board of Continental AG's Powertrain Division, said: "Today, there is a gap between relatively inexpensive 12-volt stop-start systems and more complex hybrid solutions with typical voltages between 200 and 400 volts. By tailoring the electrification solution, we are creating a modular system that allows car manufacturers to understand different hybrid levels between 12 and 400 volts. Continental Powertrain is focusing on providing cost-effective systems and products to serve our customers cost-effectively; we believe that 48-volt system solutions can support customers in reducing CO2 emissions at a reasonable cost."

48 volts, a new approach to expanding entry-level hybrid systems

    Continental believes that once OEMs have exhausted the potential of existing 12-volt electrical systems, they will turn their attention to supplementary 48-volt electrical systems. Continental's 48-volt system can provide a variety of functions that are currently only available in more complex 120-volt mild hybrid systems. Continental has already applied 48-volt architecture and other components in the innovative 48-volt Eco Drive test vehicle. The vehicle integrates 48-volt components as an optimized solution: a belt-driven 48-volt starter generator that can replace the conventional generator, seat belt tensioners with belts, 48-volt lithium-ion batteries from our battery production expert SK Continental E-motion, and DC/DC converters that can be connected to the 12-volt electrical system.

    Among the advantages of the 48-volt Eco Drive, it restarts faster and quieter – even when temperatures drop below zero – and offers a more efficient recuperation function. This means that it can deliver more current and thus save energy. "The main advantage is that the combustion engine can be switched off earlier and more frequently when propulsion is not required," explains Xavier Pujol, head of the Hybrid Electric Vehicle business unit at the Powertrain division. "With use in marine and coastal cruising, the 48-volt system allows the engine to be paused longer, which saves fuel," continues Pujol. "Our Eco Drive also offers car manufacturers the advantage that they do not have to change the configuration of the engine and transmission. The technology is also suitable for smaller cars."

Plug-in hybrid powertrains are the new growth market

    Analysis of the current landscape of electric drivetrains shows that the plug-in hybrid is the most promising hybrid system after 48 volts. This is because the plug-in hybrid vehicle can be charged via the power grid and the high-voltage battery is sufficient to travel up to 50 kilometers purely on battery power. On the other hand, the internal combustion engine can still provide full system conventional vehicle power if necessary. "Our innovative plug-in hybrid system shows that it is entirely possible to convert existing vehicles with efficient internal combustion engines into a hybrid system that can travel 100 kilometers on just 1.5 liters of gasoline, depending on the driving cycle. Its CO2 emissions are only 40 grams per kilometer," said Christian Senger, head of Continental's Systems & Integration Division.

    Continental developed the plug-in architecture independently, including an electrically excited synchronous motor (peak power of 80 kW and torque of 225 Nm), supported by a dog clutch and fixed to the rear axle of the original car. This split-axle configuration means that the innovative car has all-wheel accessories and can permanently get rid of the losses of drag. The plug-in hybrid system can travel 50 kilometers on electric power alone. According to Continental's traffic survey, 70% of private cars in Europe and the United States travel less than 50 kilometers a day.

Pure electric vehicles are developing well

    The pinnacle of custom electrified vehicles is the electric vehicle (EV). The conversion of a series production vehicle into an EV at Continental demonstrates our expertise in this field.

    Around 40 of Continental's components for electric vehicles are used in the vehicle. Many of these components are already supplied for electric vehicles in Europe. "Electrification is not only about propulsion, though, in the end. To achieve a breakthrough in e-mobility, we need new vehicles that cover all the advantages of electric drivetrain architectures," said Senger. These areas include driver assistance systems based on camera and/or radar technology, vehicle networking, and body electronics solutions for greater comfort and convenience. Intelligent electronics can help to reduce customer concerns about the range of electric vehicles. Continental's new concept car "Simplifying Your Electric Driving" uses the navigation system and data from peripheral devices to calculate the remaining driving distance. Drivers can therefore find out whether the battery is sufficiently charged or whether they need to recharge at a charging station en route.

    With sales of 32.7 billion euros in 2012, Continental is one of the world's leading automotive parts suppliers. The group's business covers brake systems, powertrain and chassis systems and components, instrumentation, infotainment systems, automotive electronics, tires and industrial rubber products, and is committed to improving driving safety and global environmental protection. Continental is also an excellent partner in the field of automotive network communications. Continental has approximately 173,000 employees in 46 countries around the world.

    Continental Automotive Group of Germany had sales of approximately 19.5 billion euros in 2012, and consists of three divisions: Chassis & Safety Systems (sales of 7 billion euros in 2012, 34,500 employees), Powertrain Systems (sales of 6.1 billion euros in 2012, 31,000 employees), and Body Electronics Systems (sales of 6.4 billion euros in 2012, 33,000 employees). Currently, the Automotive Group has more than 170 branches around the world. As a partner of the passenger car and commercial vehicle industries, the Automotive Group develops and produces various innovative products and systems to further realize automotive modernization, and is committed to a new driving experience that is safe, environmentally friendly, economical, and comfortable.

    The Chassis & Safety Systems Division develops and produces electronic and hydraulic brake systems, chassis control systems, sensors, driver assistance systems, airbag controls and their sensors, washing systems and electronic air suspension systems. Its core strength is the ContiGuard® system that integrates active and passive safety systems. The Powertrain Systems Division focuses on innovative and efficient automotive powertrain systems. Its rich product range covers gasoline and diesel injection systems, engine management systems, transmission controls, sensors and actuators, fuel supply systems, hybrid and electric vehicle components and systems. Information management is the core business of the Body Electronics Systems Division. The products of the Body Electronics Systems Division include instrument clusters and multi-function displays, control units, electronic car entry systems, tire monitoring systems, radios, multimedia and navigation systems, temperature control systems, in-vehicle information service solutions, and cockpit modules and systems.