Continental has developed global solutions for the fast-growing international market for affordable cars
Demand for smaller, low-cost cars is rising, not just in Asia and Latin America but increasingly in established industrialised nations also. A sign of the global automotive market changing rapidly within the next six years the share of total production accounted for by low-cost vehicles is set to climb to around 20 per cent. Germany-based automotive supplier, Continental has responded with a comprehensive, scalable product portfolio to satisfy the growing market for small and compact cars. Specialising in the development and manufacture of components and systems, which deliver high quality and safety at the lowest possible prices, the company is aiming at affordable cars that are not of a lower quality with only the most basic of components.While affordability has become the standard, prosperity gaps and the level of car ownership in certain parts of the world entail varying definitions of the term "affordable car". Vehicles fitting this description in India sell to end customers for the equivalent of just under Euro 2,000, while the lower price threshold in China and eastern Europe is around double this amount. Higher expectations in western Europe and Japan set the price limit for an "affordable" car with standard features at Euro 10,000. For a supplier like Continental, the term also covers vehicles in the small car and compact class, raising the price range to Euro 18,000. In Japan, one in three new cars is registered as a "Kei" car. These small, tax-privileged vehicles with a 660 cc engine is primarily bought as a second car or by people with low disposable incomes. A Kei car is considered affordable if it costs less than 1.5 million yen, around Euro 11,000.Affordable cars require highly efficient technology that is tailored to the customer and regional expectations. The utilisation of engineering capacities in the regions also has a part to play, as does the localisation of the entire value chain. At the forefront are factors like shorter development cycles and an ability to supply the market with high-quality products in large volumes. A perfect example is the Body Controller. Termed as Basic Function Controller to be more precise, this central control unit has become the focal point of an intelligent electronic system for the Asian and global markets. Developed from scratch and in a completely different way to its conventional counterparts for the European market, any features without any directly discernible function for the customer were reviewed for their necessity and avoided as appropriate.Continental, which develops cost-optimised products as well as offers the suitable and innovative system solutions, is working with its centres of excellence across the globe to turn such products and solutions into reality, combining local knowledge with the experience and expertise in the established markets. The SPEED (Safety Platform for Efficient & Economical Design) airbag control unit, developed by Continental's Chassis & Safety Division, has a modular design that can easily be adapted to the requirements of vehicle manufacturers. The multi-level concept meets the demands of all global markets and allows even entry-level models to be fitted with a high-performance airbag system. The housing for the Airbag Control Unit takes the form of a metal base plate covered by a plastic lid and can be flexibly mounted with various connectors. This in turn makes it extremely simple to adapt the electronics to the vehicle. The basic version "SPEED S" is fitted to affordable models in the small car category and is designed to control the front airbags, but side airbag control can also be added as an optional extra. The S module can control as many as twelve different components, including the airbags and the seat-belt pre-tensioners. SPEED offers great flexibility as a result, with the option of precisely tailoring the airbag control unit to the manufacturer's requirements, while largely benefiting from an identically engineered design, standard interfaces and mass-produced components. Aside from the cost benefits, this also translates into short development periods thanks to the rapid integration of the technology. Challenges for developing a new ABS for the industrialising markets was the need for a smaller, lighter and an attractively priced solution. In addition, the new system had to be as good as the ABS MK 70 that is currently in series production at Continental. Smaller vehicles and therefore less installation space made the reduction in size necessary, but at the same time, the lower engine output and lower overall vehicle weight in these markets also allowed a downsizing of the ABS unit, leading to a reduction in material costs. The next generation MK 100, which is currently in pre-production, once again cuts down dramatically on size and weight compared to its MK 70 predecessor. The Asian Base Actuation (ABA) brake actuation mechanism also incorporates a number of detailed solutions for reducing costs. Given the lower expectations of the market, the vacuum brake booster can be manufactured with a reduced material strength and thinner membrane. It also costs less to manufacture a dual master cylinder piston in steel than it is in aluminium. Callipers for the emerging markets were developed on the basis of the brake calliper module. The differing expectations of customers in Asia could be exploited to reduce costs. Given the fact that perceived annoyances such as noisy brakes have to be rectified with great effort for the European market but are not considered a problem in Asia, what matters is that they work. Interestingly, the buyers of affordable compacts and small cars should also be able to benefit from driver assistance systems that make the road a safer place. Preventive systems, for example, are set to become a reality in all vehicle classes following the introduction of mid-range radar. The sensor scans the road ahead of the vehicle to a distance of up to 150 metres and warns of impending rear-end collisions. Continental is working with vehicle manufacturers to develop lane changing and speed limit monitoring systems for market launch in the small car segment from 2011. In terms of emissions legislation, the gap between western industrialised countries and the emerging markets – predominantly Brazil, Russia, India and China (BRIC) – is closing. Whereas, in the very recent past, China lagged six years behind European regulations, the Euro 4 standard now applies in their mega cities and in ten major Indian cities as well. When developing inexpensive engine management systems, injectors, fuel supply systems, sensors and actuators, Continental's Powertrain Division draws not only on its many years of expertise gained in the established automotive markets but could also exploit the synergy effects from its Synerject subsidiary. This joint venture company, established over ten years ago together with the Orbital Engine Company, specialises in engine management systems for motorcycles, boats and other leisure sports vehicles. Consequently, development work has incorporated much of the technology used for the small one, two and four-cylinder engines in this less expensive segment; this technology transfer, especially from motorcycles to cars, will accelerate in the next few years.In addition to the innovative 32-bit "Easy-U" engine management system, which can be flexibly adapted to the relevant vehicle architecture, the total package on offer includes injectors, air volume and temperature sensors, air intake controls and crankshaft and camshaft sensors. "Easy-U" was developed at the Continental sites in France and China with the components manufactured in the city of Changchun. A newly developed transmission control module, which is marketed under the name "EAST Platform", has also gone into series production at the Changchun site. The module – a rapid-acting 32 bit controller in a compact housing – can be used for a wide variety of functions. Its control unit can monitor and control continuously variable transmissions (CVT), automated manual transmissions (AMT), double clutch transmissions (DCT) and traditional automatic transmissions.Stop-start systems that automatically turn off idling engines are particularly important in the megacities of developing countries where cutting emissions is a pressing issue. Continental's Interior Division is working on control electronics with simple designs for precisely these situations. Hybrid and electric drive technology is also gaining in importance in emerging markets. Continental, as a supplier of the complete range of hybrid technology from lithium-ion energy storage units to power electronics, is playing a significant role in promoting this technology. Several series production contracts for mild hybrid drives are currently running in China. Because the markets for affordable cars are so price-sensitive, the challenge here is to implement high-tech solutions more simply and less expensively, while at the same time delivering functionality comparable to that found in vehicles for western Europe and North America. A key role will be played by cars with purely electric drive systems, mainly intended for use as city runabouts in densely populated areas and for which there is already an increasing demand. Other than modern instrument clusters, many state-of-the-art interior features, which were previously only installed in high-end vehicles, can now be found in affordable cars. Examples include wireless data transfer via Bluetooth, simple navigation using networked radios and keyless access and control systems. All these and other products are tailored to regional market expectations and local circumstances at no loss of aesthetic. Product solutions that incorporate a diverse range of functions into one single system present an opportunity to reduce costs. A combined radio and air conditioning control unit, for example, designed specifically for affordable vehicles, reduces outlay in both manufacturing and installation. With the Advanced Function Controller, Continental has also developed a control unit with significantly greater scope for functionality and performance. In comparison with the Basic Function Controller, it offers a 32-bit processor instead of an 8-bit, twice as many CAN and LIN buses (with gateway function) and far greater functionality – for example with regard to safety and light technology such as power-operated windows with obstruction sensors. These make the Advanced Function Controller a one-stop solution for vehicles with a demanding requirements profile. Affordable cars are gaining in importance all over the world. As entry-level motorized vehicles in emerging markets, as a low-cost and economical mode of transport in industrialized economies, and as space-saving run-arounds in densely populated conurbations. In the coming years, the number of cars around the world will grow to well over 942 million, a large proportion of which will fall into the area of affordability. The small car and compact segment and the premium segment are subject to exactly the same demands: safety, focus on accident prevention and protection, fuel economy, clear information about the condition of the vehicle and simple, convenient controls. Continental Automotive Group is making this technology available to people around the world through its global network of development and production sites.