German systems supplier ContiTech has been addressing the challenges of the auto industry and has come out with hoses for rising standards

Higher performance, smaller installation spaces and more demanding customers are the typical challenges most auto manufacturers continue to face. ContiTech's fluid technology arm has developed new hydraulic, flat, and moulded hoses to enable the automakers to handle these challenges.

The dynamically high-strength flat hoses are already in series production at Porsche, providing a very large volume increase at minimal pressures. They are also planned for use in BMW and Mercedes-Benz's power steering systems. Their task is to absorb pressure and noise waves in very tight installation conditions. "The hoses achieve this by changing from their original oval form to a round hose cross-section at just over 0 to 2 bar," explains Klaus Brühne, product developer at ContiTech. This means that the hose gains about 30 per cent volume, thereby reducing the pressure peak accordingly. Irregularities in the media flow that would lead to disturbing noise are also eliminated in this way. "We've completely redesigned the hose and optimised the material to meet the large forces in limit areas," adds Brühne.

Looking at the principle that is used by the high volume, moulded hoses to optimise noise absorption in narrow installation spaces and reduce pressure peaks, optimising the polyamide tensile members has made the dynamically high-strength hoses particularly expansible, with their volume increasing during pressure peaks. In addition to applications in power steering, they are also used in gearbox oil cooling systems. The hoses have now been integrated into the modular system of ContiTech Fluid Technology, in both their oval and round forms.

Other new products include the extra-high-pressure hydraulic hoses for temperatures upwards of 120°C and pressures above 180 bar. They are used in active vehicle control systems like those offered by Daimler, BMW and PSA. "These systems are designed to compensate for body roll", explains Brühne. The high forces acting on the hoses require high compensating pressures.

Their high temperature resistance makes them ideal for the changed thermal conditions inside the engine compartment. "Engine compartments are becoming increasingly encapsulated to minimise aerodynamic drag and to house additional technology," states Brühne, explaining why temperatures there are constantly rising. The hose's superb properties were achieved by employing optimised materials and processes.