Continental brings together four strategies to reduce emissions and cut fuel consumption

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Continental brings together four strategies to reduce emissions and cut fuel consumption

     Press Release

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    Continental brings together four strategies to reduce emissions and cut fuel consumption

    More efficient drive systems, electric components for powertrain and subassemblies, weight savings through lightweight design and ergonomic assistance systems: the Automotive Group delivers scalable solutions for the automotive industry

Frankfurt am Main/Regensburg, July 20, 2009 Lowering the fuel consumption and

    emissions of cars and commercial vehicles is one of the most important issues for the future of sustainable individual mobility worldwide. The Automotive Group of the global automotive supplier Continental is bringing together four strategies to reduce fuel consumption, and will be able to offer car manufacturers a comprehensive package of solutions for the low-consumption vehicles demanded by the market. These measures will also ensure compliance with national and international legislative requirements for emissions standards and the reduction of CO. 2

“Our goal of enabling resource-efficient motoring with a reduced environmental impact

    cannot be achieved through individual measures alone. It requires a number of intelligent innovations that cover the full range of systems,” said Dr. Karl-Thomas Neumann, Chief

    Executive Officer of Continental AG and Head of the Automotive Group. “These innovations

    also have to be scalable, so that they can be offered in price-sensitive vehicle classes and markets.”

Four strategies for greener driving

    The Automotive Group is focusing on four complementary strategies to reduce the impact of vehicles on the environment and to ensure the sustainable use of resources. This integrated systems approach will help car manufacturers to bring vehicles to market that maximize fuel economy while minimizing environmental impact.


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    ; Continuous optimization of fuel and energy consumption, for example by reducing

    engine size with the help of turbocharging and direct-injection technology

    ; Electrification of the drive train and other vehicle functions through the development

    of hybrid and electric components and electric power steering

    ; Ergonomic, pro-active driver assistance systems and the use of navigational

    information by the various control units

    ; Weight-saving design through optimized manufacturing processes and selection of

    materials, as illustrated by the example of our brake calipers and electronic braking


    More efficient drive systems: lower consumption with a more enjoyable drive The dominant trend in engine development today is “downsizing”: engines with a lower cubic

    capacity but greater specific power. This can only be achieved by the use of turbocharging. The Powertrain division has now brought the first turbocharger system for internal combustion engines to market maturity. The combination of small cubic capacity, direct injection and optimized valve timing with high specific power allows the engine to operate within ranges which are thermodynamically highly efficient. Turbocharger technology and

     emissions to be reduced by up to 15 percent. Clever innovations downsizing enable CO2

    include the automated assembly of the turbocharger and the electronically controlled e-wastegate system that will be available in the future. This offers faster control and greater precision than conventional systems, and thus increased scope for reducing fuel consumption. The modular design also makes the turbocharger easy to adapt to a variety of engine sizes.

    Direct injection systems for diesel and gasoline engines deliver high performance and maximum torque while keeping consumption low. The Powertrain division is facing up to the challenges posed by the introduction of the Euro 6 emissions standard with its latest generation of piezo injection nozzles for the diesel engine. The degree and length of time the injector is open can be controlled more precisely when the nozzle needle is directly influenced by the piezo element without the need for an intermediate hydraulic system. This allows the option of injection rate shaping as an alternative to the usual multiple injection method used in the past. With this design, the piezo actuator acts as a sensor by reporting


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    the precise position of the nozzle needle to the control unit, producing the first self-contained

    emissions to be reduced by 20-flow rate control system. Piezo direct injection enables CO2

    25 percent compared with an engine with a traditional manifold injection system. The combination of brushless fuel pump (EC pump) in the supply unit and electronics to regulate demand produces an additional saving of 1-3g CO per 100km. 2

    Automatic transmissions will play an increasingly important role in the market. This will require precise gearshift control so that the engine operates as often as possible within speed ranges which consume the least fuel. As the global technology leader in the transmission control market, Continental can supply control systems for the complete spectrum of automatic transmissions. The double clutch transmission in particular combines the convenience of an automatic transmission with the efficiency of a manual system.

    The innovative technologies for exhaust aftertreatment and thus for the reduction of emissions also extend to essential components in the exhaust pipeline. Continental sensors measure variables such as exhaust gas temperature, soot or NOx content and work out how efficiently the catalytic converters are operating so that regenerative or regulative countermeasures can be initiated by the injectors in the exhaust pipeline. This improves particulate filter regeneration and the control of the SCR system for the selective catalytic reduction of nitrogen oxides. Continental also has a strong partner for catalytic converter technology, thanks to the 50 per cent stake it has taken in Emitec.

    Electrical components for powertrain and subassemblies save fuel

    The transition from internal combustion engine to the zero-emission electric car of the future is already well underway. A representative survey of German motorists carried out on behalf of Continental in spring 2009 showed that almost one in nine car drivers can “entirely”

    imagine switching to an electric car for their next vehicle.

    “The stated aim of Continental is to consolidate its leading position as a supplier in this field,” stressed Dr. Neumann. “50 percent of the global population already live in or near urban

    areas, which makes the possibility of completely emissions-free driving in those areas ever more important.” Hybrid and electric drive systems go a long way towards achieving this


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    objective. For the hybridization or electrification of the drive train, the Powertrain division has developed a modular system for car manufacturers which can be used flexibly in mild, full and plugin hybrids, fuel-cell and electric vehicles. This enables fuel savings of up to 25 percent if used in conjunction with a conventional combustion engine, while electric vehicles are completely emission-free.

    At the end of 2008, Continental also became the first manufacturer in the world to commence series production of lithium-ion batteries for use in hybrid vehicles. The latest generation of lithium-ion accumulators offer a significantly higher storage capacity compared to the nickel-metal hybrid batteries currently in use. In addition to batteries, Continental's hybrid module offers power electronics, the electric motor and complete system solutions including integrated powertrain management as core components of hybrid systems.

    Hybrid technology will soon also be introduced for drive trains in commercial vehicles. Goods distribution trucks and buses in densely populated areas will be able to save around 30 percent on fuels, as they predominantly travel short distances in “stop and go” traffic which is where the advantages of the hybrid drive really come into their own. In addition to the existing agreement for passenger cars, Continental has recently signed an agreement with ZF Friedrichshafen with regard to a partnership in the commercial vehicles sector. Continental will contribute the latest generation of lithium-ion batteries to this project.

    Energy management and electric power steering: Auto manufacturers will have to

     emissions of their vehicles - particularly heavier vehicles - in significantly decrease the CO2

    order to avoid severe punitive taxes. In some European countries, these can already reach four or even five-figure sums (in euros) for heavy sedans or SUVs. As a first step, these vehicles will be equipped with stop-start systems. In order to secure the onboard power supply, Continental offers an energy management system which can cover all electric components. The electrification of subassemblies such as the power steering or coolant pump, in which conventional, energy-guzzling hydraulics are replaced by an electric drive, will result in further considerable potential for savings. The Chassis & Safety division has developed a modular power pack comprising control electronics and electric motor which enables electric power steering to be fitted in large sedans or SUVs which have 12-volt


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    onboard networks. Electric power steering systems achieve noticeable fuel savings because they only need energy while they are actually working, whereas hydraulic pumps have to be permanently supplied with power. Depending on the steering concept, the use of electrically assisted steering can save 0.2 - 0.4 liters of fuel per 100 kilometers.

    The intelligent battery sensor (IBS) developed by the Interior division is a small but crucial component of the stop-start system in today's vehicles. The sensor continuously analyzes the charge level of the 12-volt battery. This makes sure that the starter battery has sufficient charge to guarantee the power supply to all other vehicle systems during the “stop” phase and enough power to restart the engine. When the battery is full, the sensor can also supply information to say that no further charging is required from the dynamo. This also reduces the workload of the engine, decreases consumption and makes stop-start systems more reliable. The brief drop in voltage of the vehicle's onboard power supply caused by the automatic starting of the engine is covered by the buffer provided by the DC/DC converter. This way infotainment functions like radio and navigation systems continue to function uninterrupted.

Driving foresighted: more comfort, greater safety, lower fuel consumption

    Adopting a defensive driving style has a major effect on a vehicle's fuel or energy consumption, and this is where driver assistance systems come into their own. Originally developed to enhance driving comfort and improve road safety, they can also deliver additional benefits in terms of reducing fuel consumption. For example, the Adaptive Cruise Control (ACC) ensures a smoother driving style which in turn reduces wear and fuel consumption. From 2013, emergency brake assist systems will be mandatory in new heavy goods vehicles. The ASR 300 sensor developed by the Chassis & Safety division is able to track other vehicles until they come to a complete standstill, and to simultaneously slow the truck down as well. This “Follow to Stop” function makes life easier for the driver, especially

    in slow-moving traffic, and prevents minor rear-end collisions, which cause long traffic jams

    -emissions. and, as a consequence, unnecessary CO2

    Even in heavy traffic, the Accelerator Force Feedback Pedal (AFFP) developed by the Chassis & Safety division helps drivers to keep a safe distance from the vehicle in front and


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    to maintain as constant a speed as possible. The system uses information from the various vehicle sensors, identifies the best speed for staying with the flow of the traffic, and lets the driver know if he is about to exceed the optimum speed range by accelerating too quickly. The result is that the vehicle maintains an even engine speed and braking and accelerating actions are significantly reduced. The driver can be alerted in a variety of ways, either by the pedal gently vibrating or pulsating or through the exertion of a counterpressure. AFFP can also indicate the ideal time to change up to the next gear. In trials, it was found that the driver followed the recommendation far more frequently than when information was presented visually. AFFP enables fuel savings in excess of 10 percent.

    The “electronic horizon” provides information on the road ahead to all other onboard systems, such as engine control and battery management. Using data supplied by the “electronic

    horizon”, the engine and transmission control units can adapt gear-changing strategies to the

    road ahead and further increase vehicle efficiency. Cruise control, other driver assistance systems and the hybrid control unit can also use the data and, for example, run off the battery when the vehicle is approaching a downhill section. This ensures that the energy gained from braking during the downhill section (recuperation) can also be used in the accumulators. In electric cars, the navigation system will calculate the route in a way that makes it possible to easily reach the available battery charging or battery changing stations.

    Correct tire pressure can help to save fuel. The tire pressure monitoring system (TPMS) increases road safety and reduces consumption. Around 90 percent of all tire failures are caused by slow punctures which can lead to serious accidents, particularly at high speeds. The monitoring system developed by the Interior division can detect, separately for each tire, whether the actual pressure varies by more than 10 percent from the specified pressure and can then sound an alarm. Across Europe, ?3.4 billion could be saved every year if every

    vehicle's tires were inflated to the correct pressure.

    reduction starts with weight CO2

    More efficient design techniques and intelligent lightweight construction can produce slimmed-down components without limiting their functionality. The Chassis & Safety division is using software-based optimization systems to put this principle into practice. Special CAD


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    software was used to optimize the structures of the 2FNR-Al aluminum brake caliper housing, for example. Despite bigger recesses and reduced wall thicknesses, meaning less material is required, the optimized housing provides the same degree of stability as the tried and tested model even though its weight has been reduced by 440 grams to 4,185 grams Thanks to a special manufacturing technique, new brake pad backplates are thicker only in the highly stressed areas. In all other areas thinner material is used. This allows a saving of around 300 grams per brake without additional costs or losses in performance. It is also possible to reduce weight by up to 40 percent in the brake actuation mechanism, for example by using aluminum. The housing of the MK100 ESC system is not just 40 percent smaller than its predecessor, but also weighs 22 percent less. The greater integration of control units also enables weight savings to be achieved, as less housing and fewer mountings are required, and in particular there is no need for extensive cabling.

Last, but not least: the critical role of the driver

    Ultimately, the driver also has to be committed to the idea of fuel economy, and the combination of two different approaches appears to produce the best results in terms of getting drivers onboard. The first is to provide clear information about what the vehicle is capable of such as the active accelerator pedal (AFFP) mentioned above. The second is to allow the driver to set all vehicle systems to a particularly energy-efficient or fuel-efficient operating mode. In contrast to a more sporty setting this can lead to additional reductions in fuel consumption. The Continental Automotive Group's approach in this field is Simplify your

    Drive." At the touch of a button, the driver will be able to quickly and easily change the character of the vehicle from sporty and extremely agile to highly economical. For that purpose the individual in-vehicle systems’ control units collaborate to achieve the biggest possible efficiency gain.

    With sales exceeding ?24 billion in 2008, the Continental Corporation is one of the top automotive suppliers worldwide. As a supplier of brake systems, systems and components for the powertrain and chassis, instrumentation, infotainment solutions, vehicle electronics, tires and technical elastomers, the corporation contributes towards enhanced driving safety and protection of the global climate. Continental is also a competent partner in networked automobile communication. The corporation currently employs approximately 133,000 at nearly 190 locations in 35 countries.

    The Automotive Group is one of the leading global automotive suppliers. With its three Divisions Chassis & Safety (5.1 billion ?, 27,000 employees), Powertrain (4 billion ?, 25,000 employees) and


     Your contact: Simone Geldhäuser, +49 941 790 61302

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    Interior (5.9 billion ?, more than 30,000 employees) it achieved sales of approximately 15 billion ? in 2008. The Automotive Group is present in more than 130 locations worldwide. As a partner of the automotive and commercial vehicle industry, it develops and produces innovative products and systems for a modern automotive future, in which a car accommodates individual mobility and driving pleasure to driving safety, environmental responsibility and cost-efficiency.

    The Chassis & Safety Division develops and produces electronic and hydraulic brake and chassis control systems, sensors, driver assistance systems, air bag control systems, washer systems as well as electronic air suspension systems. Its core competence is the integration of active and passive driving safety into ContiGuard?. The Powertrain Division integrates innovative and efficient system

    solutions for vehicle powertrains. The comprehensive range of products includes gasoline and diesel injection systems, engine management, transmission control, including sensors and actuators, as well as fuel-supply systems and components and systems for hybrid drives. Information management is at the very heart of the Interior Division. The range of products includes instrument clusters and

    multifunctional displays, control units, electronic car-entry systems, tire-monitoring systems, radios, multimedia and navigation systems, climate control systems, telematics solutions as well as cockpit modules and systems.

Contact for journalists:

Simone Geldhäuser Nicole Geißler

    External Communication External Communication

    Continental Continental

    Powertrain Division Chassis & Safety Division

    Siemensstr. 12 Guerickestraße 7

    93055 Regensburg 60488 Frankfurt am Main

    Tel.: +49 941 790-61302 Tel.: +49 69 7603-8492

    Fax: +49 941 790-99 61302 Fax: +49 69 7603-3945

     Enno Pflug

    External Communication


    Interior Division

    Sodener Straße 9

    65824 Schwalbach am Taunus

    Tel.: +49 6196 87-2515

    Fax: +49 6196 8779-2515

     Your contact: Simone Geldhäuser, +49 941 790 61302

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