Increasing demand for alternative powertrain concepts in the CV market.
Overview
- Market Demands
- Our Portfolio – Our Solution
- Our Sustainability Ambition
- Partner
- Our Offer
Market Demands
Worldwide emission regulations – OEMs need to move fast to bring their solutions to market.
Technological uncertainties with regards to energy carriers, low volumes and high investment costs make profitable investments harder.
Charging infrastructure will need to be developed to guarantee reach and availability also for commercial vehicles.
Sustainability: Prove CO2 neutral production + global CO2 emissions also valid for trucks.
In this complex field, manufacturers need an experienced partner to help them deliver the right solutions.
Our Portfolio – Our Solution
With our holistic approach, we offer a comprehensive portfolio in e-vehicle hardware and software.
From requirements definition and consulting to pre-development demos, up to the SOP and after series support – we deliver solutions along the complete product lifecycle.
This deep know-how is completed by our substantial product range for all hardware and software solutions for e-vehicles and infrastructure.
Our Sustainability Ambition
Our Key Ambitions
By 2050 at the latest, we and our value chain partners are striving for:
100% Carbon neutrality
along our entire value chain
100% Emission-free mobility and industry
100% Circular economy
100% Responsible value chain
Good working conditions
Safe mobility
Green and safe factories
Long-term value creation
Innovations and digitalization
Sustainable management practices
Benchmark in quality
Corporate citizenship
Continental - Your Partner for E-Mobility
With decades of CV specific customer experience for architecture, electronics, a dedicated electronics development team and a global CV organization, we are well equipped to cover all customer needs around EV electronics.
- On the way to zero emission production (carbon neutrality)
- Dedicated development team with 500+ employees focused on electrification solutions worldwide
- Development and validation infrastructure: testing, vehicle workshops, test benches
- Global manufacturing footprint for low, mid, and high volumes with reuse of manufacturing investments
- Many years of experience in electrification with proven track record
- Cybersecurity + functional safety expertise
Our Offer – High Level Overview
We are your partner of choice towards emission free mobility in the CV market. We offer solutions for E-Mobility along the complete product lifecycle in the areas of:
Architecture & Consulting
System Integration, E/E-Architecture, Vehicle development and prototype build
Software
Basic Software, Application Software, Autosar
Product Development & Products
Power Electronics (up to 1000 V), Low Voltage Electronic Control Units , Powertrain Auxiliaries
Architecture and Consulting
One Stop Shop Partner
- Feasibility Studies
- Requirements
- Topologies, E/E-Architecture
- Component Dimensioning
- Performance Simulation
- Development Plan
- Component Development
- Vehicle Development
- Software and Control Development
- Technology Demonstrators
- Test Vehicles
- Fleet Vehicles
- System Integration
- Commissioning
- Logistics
- Performance
- Robustness and Reliability
- Safety and Misuse
- Crash Tests
- Prove of Legal Compatibility
- Homologation
- NEV Market Entry
- Industrialization
- Launch Support
- Production Support
Software
- Service Overview
- Platform and AUTOSAR Competence
- 4th Generation of Software Development
- Agile Planning Approach
While the customer can focus on SW development, we ensure the industrialization of the product.
Benefit from SW/HW experienced supplier with comprehensive AUTOSAR and security competences.
- Model-Based-Development-System for efficient application development.
- Wide portfolio and experience in the area of E-Mobility/driveline, body and chassis applications.
We master base software and complexity of integration (customer-, Continental- or third-party SW parts) while customer can focus on his core competences /
application level.
Benefit from 4th Generation of embedded platform
- Model-Based-Development-System
- Aligned HW to accelerate time-to-market
- Agile framework and strong automotive partners
Customer software care and competencies needs
Platform and AUTOSAR Competence
4th generation of embedded platform covers AUTOSAR complexity by advanced toolset to accelerate development:
Configuration instead of Programming
Applicable for all kind of embedded devices
- Easy-To-Use tool chain allows application development and integration by customer
- Expert tool chain for projects with needs for highest flexibility and adoptability
Manages embedded challenges as
- Different processor families and multicore
- Scalable connectivity
- Safety (up to ASIL-C)
- Security and many more
Generation CoVeR
- AUTOSAR
- Security
- Hybrid, Connectivity
- MultiCore
Generation RT3/RT3-PL
- Multi Tasking
- ASIL B
- PremiumLine ARM Core
- LogiCAD 3
Generation RT2
- Matlab/Simulink
- Generic CAN
- FR80 Core
Generation RT1
- Model based development
- LogiCAD 32BIT µC
- VGC Core
- More than 18 years of System Solutions Experience
- Focus on development cost optimization for OEM
- Focus on improve Time to Market
4th Generation of Software Development
Unique approach with focus not only on target software, allows
- Benefits of high reuse of existing HW and SW solutions
- The seamless integration of development tools for high automation and focus on the essential tasks
Needs to support the wide spectrum of commercial vehicle electronics
- Applied for Body controller, vehicle control units, Instrument cluster
- Used in more than 100 projects
Ready also for E-Mobility applications
Agile Planning Approach
Agile development improves
- Focus on features with highest value added
- Flexible re-prioritization of development targets
- Avoiding wasted planning and process efforts
Rolled-out agile process based on SAFe
(Scaled Agile Framework)
Product Development & Products
Product Overview
- DC/DC Converter
- Battery Management System (BMS)
- Pantograph (eHighway)
- Electric Vehicle Charging Controller
- Receives and processes data from the connected sensors and actuators and provides output signals to other ECUs on the Auxiliary CAN.
- Provides control interfaces to the connected sensors/ actuators via signal interfaces on the Auxiliary CAN.
- Acts as an intelligent gateway ECU and contains SW to fulfill the standard
diagnostic and network requirements. - Needs to process signals and execute OEM in-house functions.
- All electric long-haul truck (Tractor/ rigid)
- Can Interface: CAN-FD
- Operating Temp.: -40…+105°C
- IP Class: IP6K9K
- ASIL: B
- The Vehicle Charging Controller is a generic 12V/24V Unit for use in electrified commercial vehicles.
- It realizes electrical charging according to DIN and ISO requirements for power line communication (PLC and MCS) with the infrastructure needed at EU, NA and Asian Market.
- Full electric target vehicles are light, medium and heavy trucks, solo and articulated buses.
- The HW will be designed and produced by Continental, programmed with customer developed software and charging application.
- ASIL-B to ASIL-D hardware design possible
- Variants, realized on same PCB with diff. component assembly
- OEM specified connector
- Separate connectors to adapt the Variants to periphery
- Optional foreseen Ethernet single Phy
- IFX Controller TC3xx, BGA516
- Several IO hardware interfaces for infrastructure needed at EU, NA and Asian Market
- 2...5CAN interfaces, LED signal drivers for inlet covers OEM needs
- Housing IP-Class IP50 to IP6k9k covers OEM needs
- Mounting in cabin, on Frame or top on roof for busses
- Different variants are planned to cover known truck and bus applications at different markets.
- The Controller will be built and delivered as standard unit and in an extended version with Ethernet functionality
- The standard unit be used as an interface controller with full support of cable-based inlets.
- The extended version, be an interface between vehicle side and the charging station, with full support of cable-based inlets, roof mounted pantograph and inverted pantograph.
The Continental Power Line Communication controller provides a modern and smart PLC to CAN gateway to the car and its passengers. It is the communication interface between the Electric Vehicle Supply Equipment (EVSE) and the Electric Vehicle Central Control Unit (vehicle charging functions).
- AC/DC fast charging communication
- Plug and Charge (PnC)
- Bidirectional Power Transfer (BPT)
- Self-Test and Diagnostics via UDS
- Smart Charging
- Safety ASIL B (D)
- FOTA (over-the-air update) capable
- IP42 (optionally IP6k9k)
- Dimensions: 70mm x 120mm x 27mm
- Weight: 110g
- Provide operating system and hardware abstraction software in AUTOSAR environment
- Provide Continental application software, Adapt functional to OEM specificities
- Support System Integration and System Test
- Support prototyping, qualification
- Industrial encapsulation and production launch
- Deliver serial parts – Reduced time to market
- Compliant with PLC norms ISO 15118 and DIN 70121
- CHAdeMO supported optionally
- Charging Communication over CP signal according to IEC 61851
- Modular Design allows for easy individualization and integration of 3rd party applicative software
- Cyber security concept protecting against external threats and including secure
reprogramming using a dedicated HSM core - Up to ASIL D Charge System Performance
- Proven in series application - Reduced time to market
- Acoustic Vehicle Alerting System (AVAS) is an obligatory sound generator for electric and hybrid vehicles that generates a synthetic speed related driving sound to increase the pedestrian’s and other road user's safety by alerting them about an otherwise silently approaching vehicle.
- The system consists of an ECU and 1 (basic) or up to 5 (premium) actuators which can be mounted to any exterior body structure.
- Extra wide radiation of sound due to excitation of the surface
- Flexible integration due to small dimensions and weight
- Higher resistance against media than a conventional speaker (water, dust and shock)
Ac2ated Sound
- New design possibilities
- Natural sound
- Fewer channels/parts
- Scalable system
- Completely invisible
- Less volume/weight
- Reduced cost
Overview ECU
- Operating voltage 12V/24V (9…32V)
- Operating temp.: -40°C to +85°C
- Class D amplifier
- 15W-35W / channel
- CAN-FD supported
- Protection class: min. IP6k9k
- 2MB Flash (optional 8MB available for WAV files)
- Weight: approx.: 250g
- Dimensions: approx. 110 x 120mm
Overview Basic Transducer
- Operating temp.: -40°C to +105°C
- Power rating: TL 10W; ST 20W
- Frequency range: 200Hz -20kHz
- Protection class.: IP6k9K
- > 90dB (SPLmax)
- Impedance: 4Ω
- Weight: 68g (incl. housing)
- Dimensions: 31.8 x 56.8 x 18.6mm (incl. housing)
- Compliant with PLC norms ISO 15118 and DIN 70121
- CHAdeMO supported optionally
- Charging Communication over CP signal according to IEC 61851
- Modular Design allows for easy individualization and integration of 3rd party applicative software
- Cyber security concept protecting against external threats and including secure
reprogramming using a dedicated HSM core - Up to ASIL D Charge System Performance
- Proven in series application - Reduced time to market
- Connection and charging are carried out automatically; no precise parking necessary
- 360° self centering conductive connector
- Vehicle and Ground Unit are dirt, water and touch protected until contact established
- Ground Unit is plug & play installation
- Vehicle Unit Dimension: 226/332 x 190 x 37 mm
- Vehicle Unit Mass: ~ 2 kg
- Ground Unit Dimension: 795 * 440 * 68 … 77 mm
- Ground Unit Mass: ~ 25 kg
- Working area: 400 mm diameter
- Charging Power: AC up to 22 kW, DC up to 50 kW
- Vehicle Unit Interface: AC/DC power, CAN to the vehicle, WLAN to the Ground Unit
- Ground Unit Interface: Power (AC/DC) and CP/CC to the Wall Box infrastructure via Mode 2 connector or fix installation
Ac2ated Sound
- New design possibilities
- Natural sound
- Fewer channels/parts
- Scalable system
- Completely invisible
- Less volume/weight
- Reduced cost
Overview ECU
- Operating voltage 12V/24V (9…32V)
- Operating temp.: -40°C to +85°C
- Class D amplifier
- 15W-35W / channel
- CAN-FD supported
- Protection class: min. IP6k9k
- 2MB Flash (optional 8MB available for WAV files)
- Weight: approx.: 250g
- Dimensions: approx. 110 x 120mm
Overview Basic Transducer
- Operating temp.: -40°C to +105°C
- Power rating: TL 10W; ST 20W
- Frequency range: 200Hz -20kHz
- Protection class.: IP6k9K
- > 90dB (SPLmax)
- Impedance: 4Ω
- Weight: 68g (incl. housing)
- Dimensions: 31.8 x 56.8 x 18.6mm (incl. housing)
Sensors
- Continental has developed a shunt-based current sensor for automotive applications for High Voltage Batteries in Hybrid or Battery Electric Vehicles. The sensor provides information about current, voltage and isolation independently to Battery Management System. The Current Sensor Module (CSM) communicates via CAN interface.
- High Voltage range: 400/ 800V
- Current measurement range: ±2000 A
- Current measurement accuracy: ±1.0 %
- Ambient temperature range: -40 °C … +85 °C
- Voltage measurement accuracy: ± 1,5 % (optional)
- Temperature Measurement range: -40 °C … +125 °C
- High precision safety relevant current measurement
- Supports up to ASIL D on system level by shunt / magnetic current sensors
- Compact design with integrated bus bar
- Galvanic separation of high voltage and low voltage area
- High speed measurements enable fast reaction on BMS level (e.g., battery cut-off)
- The shunt-type IBS continuously analyzes the status of conventional 12-Volt lead acid batteries and provides information on such key parameters as the state-of-charge, state-of-function (power ability) and state-of-health (aging) of the battery. The sensor is thus essential to the reliable operation of automotive start-stop systems. The IBS is mounted directly onto the battery and fits exactly into the niche around the negative terminal.
- Measurement range voltage: 5 V up to 18 V
- Measurement range current: -1500 A up to 1500 A
- Maximum Current for 2h (T<85°C) -200A up to 200A
- Accuracy SOC: 10 %
- Accuracy SOH: 10 %
- Accuracy SOF: 500 mV
- Operating temperature: -40 °C up to 105 °C
- LIN Communication
- Supports CO2 reduction measures, such as intelligent alternator control or start/ stop function
- Helps to avoid vehicle breakdowns caused by early warning of battery breakdown
- Provides the battery’s State-of-Charge (SOC), State-of-Health (SOH), State-of-Function (SOF)
- Measures the angular position of the rotor shaft in synchronous electric motors also at high speeds and accelerations with low delays.
- Integrated sensor protection for use in harsh outdoor environments.
- Generic sensor works with various pole pair e-motors.
- Sensor signal is needed for an efficient torque control in electric and hybrid vehicles.
- Protection Class: IP6K9K
- Operating Temperature: -40°C to 150°C
- Operating Supply Voltage: 2.7V – 5.5V
- Current Consumption: max. 10mA
- Rotation Speed: 30.000 RPM
- Low current consumption
- Sensor housing is smaller and lighter
- Seals the shaft of the e-motor and provides cost-efficient assembly
- No front-end-filtering function
DC/DC-Converter
- The DC/DC transfers energy between the different power nets in the vehicle
- All variants are compliant to relevant EMC standards, voltage ripple and dynamic requirements
- Development according to state-of-the-art automotive standards including functional safety and cyber security
- Silicon, Silicon carbide and Gallium nitride technologies
- Passive and liquid cooled version
- LV/LV DC/DC
- HV/LV DC/DC
- HV/HV DC/DC
Continental 48V/12V DC/DC converter – Gen1
Continental 48V/12V DC/DC converter – Gen2
- LV/LV DC/DC
- Highlights
- Overall Characteristics
- Cost efficient design
- Motor compartment compliant
- High efficiency (>97%)
- ISO26262 compliant, ASIL B
- Type: Bi-directional operation (buck/boost mode)
- Dimension (L x W x H): 213 x 187 x 70 mm
- Mass: 1.4 kg
- 12V operating voltage: 8V – 15.5V
- 48V operating voltage: 24V – 56V
- Power level: 1.78 kW (buck mode), 1.00 kW (boost mode)
- Efficiency: Typically > 97%
- Cooling: Naturally cooled
- Control: CAN
- Environmental sealing: IP6k6k / IP6k9k
- Power Target:
Buck mode: 3.5kW continuous (4.2kW short time 5s)
Boost mode: 1kW continuous - Peak Efficiency:
96.5% @3.5kW - Connectors:
3x sealed stud bolt power connectors M8 (CL40, CL30, CL31).
1x vehicle connector with 12 Pins (CL30e, CL31e, CL15, 2x CAN) - 48V Operating Range:
Unlimited operating range: 36..52V
Limited operating range: 31..36V and 52..54V - 24V Operating Range:
Unlimited operating range: 10..32V
Limited operating range: 8..12V and 32..36V - 12V Operating Range:
Unlimited operating range: 6..16V
Limited operating range: 16..18V - Software
EB AUTOSAR platform on 2-core µC
Security, UDS, J1939, Secured debug interface - Safety
ASIL-B (functional safety concept is defined by customer) - Cybersecurity
Yes - Protection
Voltage, Current and Temperature - Size
Approx. length 280mm x width 175mm x height 70mm - Volume
~3,5 lts - Weight Target
~2,2 kg - IP Rating
IP67 + IP69K w/ plugged mating connectors - EMC Filter
Yes
- HV/LV DC/DC
- Highlights
- Overall Characteristics
- Compact Design
- Easy to integrate
- High efficiency (>97%)
- Type
Buck DC/DC converter - Dimension (L x W x H)
260 x 200 x 55 mm (w/o interfaces) - Mass
4 kg - Input voltage
270V – 450V (normal operation) - Output voltage
10V – 48V (@ UIN>270V) - Peak power
2x5kW for 50s @ 4l/min at 65°C coolant temperature - Efficiency
Typically > 97% - Cooling
Liquid cooled - Control
CAN - Environmental sealing
IP6k9k (A-Sample IP54)
- HV/HV DC/DC
- Highlights
- Applications
- Overall Characteristics
Features
- Pre-charge functionality
- Self-protection via derating, integrated diagnostics
- Digital voltage and current control
- Silicon Carbide for high switching frequency
- 83kW Peak power
- 50kW continues power
- High efficiency (>97%)
- ISO26262 compliant, ASIL C
- Applications with two different power sources (e. g. fuel cell and high voltage batteries)
Type
Bi-directional operation (buck/boost mode)
Dimension (L x W x H)
310 x 240 x 210 mm
Mass
< 10kg
Boost mode
Input Voltage Range (VA): 180V to VB
Output Voltage Range (VB): VA to 820V
Buck mode
Input Voltage Range (VB): VA to 820V
Output Voltage Range (VA): 180V to VB
Power level
50 kW cont. / 83kW peak
Efficiency
Typically > 97%
Cooling
Liquid cooled
Control
CAN
Ambient temperature
-40 to +85°C
Battery Management Systems (BMS)
- The BMS monitors and controls the cells in a battery to provide the optimal performance and a safe operation.
- Development of BMS solutions according to state-of-the-art automotive standards including functional safety and cyber security
- Application SW with sophisticated BMS features (Diagnostics, SoC, SoH, Thermal Management,…), and AUTOSAR basic SW
- Component Overview
- Possible Application Software Work split
BMC
Battery Main Controller Aurix TC3 with Infineon SBC 3x CAN FD Main Battery IC Crash Interface H2 gas sensor
BDU
Battery Disconnect Unit HV Voltage and Current measurement Basic Isolation monitoring
CSE
Daisy Chain Battery ICs Cell Voltage and Temperature Measurement Load balancing (resistors external)
Usual SW Work split
CES provides:
- AUTOSAR based BSW
- Main Battery ASW
Customer function content:
- Battery cell algorithms and diagnostics
- Can also be provided by CES
ASW
- Cell Overvoltage
- Cell Undervoltage
- Cell Overtemperature
- Current Limit (I2 t)
- Continuous Current Limit (>?)
- Contactor Control
- Communication with CSE
- Isolation Measurement
- Clamp 30c Monitoring
- Interlock Monitoring
- Pack Overvoltage
- Pack Undervoltage
- ECU Identification
- Customer ASW Handler
- State of Charge
- State of Health
- State of Energy
- Operating Window
- Operating Window Violation
- In-Use-Histogram
- Cell Balancing
- Features
- Specification
- Maturity
- Automotive grade cells
- Automotive grade integrated BMS ( FSM: ASIL C, Cyber Security)
- Integrated Solid-State Switch
- Removable (hot swap)
- Combination of multiple packs possible
- CAN Communication
- Nominal energy 1,6 kWh
- Peak current: 230A (~11,5 kW)
- Continuous current: 200A (~10 kW)
- Mass: ~9,5 kg
- LxWxH: 370mm x 90mm x 230mm
- A-Sample available
- Overview
- Features & Specifications
- Block Diagram 48V Battery
- Support Multiple Li ion Chemistries (NMC,LFP etc.)
- Supports continuous current 75 Amp & Peak Current 150 Amp for limited time
- In build pre-charge circuit available
- Continuous monitoring of critical parameters i.e., Voltage, Current, Temperature, Isolation etc.
- ISO26262 complaint, ASIL C
Type
Battery Management System
Cell Configuration
3 to 16 Cells in Series
Cell Voltage range
0.5 to 5 Volts
Balancing current per cell max
150 mA
Continuous Charge / Discharge current
75 Amp max
Peak Charge / Discharge current
150 Amp max
Operating Temp.
-25 to +60°C
Storage Temp.
-40 to +85°C
Communication
CAN 2.0B
Wake Up Input
External Wk-Up available (5- 60 Volts)
- Cell voltage supervision and balancing
- Pack voltage and current supervision
- SOC/SOH calculation and power prediction
- ISO 26262 capable (ASIL C)
- Cyber Security capable
- Integrated Solid-State Switch
- Electronic fuse
- Integrated pre-charge circuit
- up to 14s
- 3 temperature sensors
- Peak current: 230A
- LxW (mm): 255mm x 75mm
- SOC calculation
Control of solid-state switches - SOH calculation
Pre-charge control
- SOC calculation
Fuse blow detection
- SOH calculation
Fuse aging monitoring
- Power prediction
Pyro Fuse Firing circuit Data histogram
Pyro Fuse Diagnostic circuitry
- SOC calculation
Coolant flow rate acquisition - SOH calculation
Coolant temperature determination
- Power prediction
Coolant control (fan, pump, valve)
- SOC calculation
Fault Management - SOH calculation
UDS Diagnostics - Power prediction
Supply voltage monitoring - Data histogram
Vehicle Communication - Battery current sensing & monitoring
ECU Power Management - Passive cell balancing
Wakeup Management
- SOC calculation
Thermal monitoring - SOH calculation
Crash Signal sensing
- Power prediction
Cell voltage sensing & monitoring - Data histogram
Cell temperature sensing & monitoring
- Battery current sensing & monitoring
Pack Voltage measurements
- Highlights
- Overall Characteristic
- Maturity
- Application
- Battery cut off
- Homogenous sensing including vehicle variants
- Driver information & warning / contact information
- Severity of damage/repair recommendation
Temperature range
-40°C … 120°C
Protocol
PSI5
Functional Safety
up to ASIL B(D)
- similar design in series production > 10 years
- SOP ~2 years after nomination
Tube with 2 pressure sensors
- tube compression
- sensor signal
- algo
- system reaction
One Stop Shop from Concept to Serial Production
- Concept Phase
- Development Phase
- Vehicle Integration and Build
- Testing and Validation
- Support and Approval
- Feasibility Studies
- Requirements
- Topologies, EE-Architecture
- Component Dimensioning
- Performance Simulation
- Development Plan
- Component Development
- Vehicle Development
- Software and Control Development
- Technology Demonstrators
- Test Vehicles
- Fleet Vehicles
- System Integration
- Commissioning
- Logistics
- Performance
- Robustness and Reliability
- Safety and Misuse Crash Tests
- Prove of Legal Compatibility
- Homologation
- NEV Market Entry
- Industrialization
- Launch Support
- Production Support
Thermal Management Competencies
- Cooling and heating of the cabin by conversion of electrical energy
- Modelling of components and control algorithm including energy and thermal management
- SW development and Virtual Test of SW functions
- Optimization of control algorithms based on requirements
- Energy optimized algorithm‘s for electric vehicles
Aerodynamic Simulation
CFD Analysis
Aerodynamics Appendage
Overview
- Evaluation of the aerodynamic efficiency of vehicle using detail steady and unsteady CFD analysis
- Minimization of drag, emissions and energy consumption
- Recommend aerodynamics appendage
- Optimization of vehicle efficiency and consumption
- Optimization of downforce/drag ratio
- Improve aeroacoustics behavior
xEV Vehicle Build & Commissioning
Building up xEV prototype along vehicle development from first technology demonstrator to close-to-series test vehicle
Services
- Engineering
- Vehicle build
- Vehicle commissioning
- Definition of interfaces to remaining vehicle
- Packaging components and systems into the vehicle
- Creation of E/E harnesses (low voltage, high voltage)
- Ensure communication of components and remain system
- Donor vehicle disassembly to BIW
- BIW modifications
- Mechanical and electrical integration
- Integration of refrigerant and coolant circuit
- Jig & Fixture design & build
- Harness troubleshooting & rectification
- Software alignment and updates (all ECUs)
- HV safety commissioning (2 levels)
- ADAS systems & chassis alignment
- Full vehicle static & dynamic testing and mileage accumulation
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