Gearing up for tomorrow. English. A Member of the Schaeffler Group

Gearing up for tomorrow English A Member of the Schaeffler Group

We are there for you! Our attention is focused towards you, your projects and your future vision for tomorrow s automotive world. In fact, over 8,000 LuK Group employees are there for you. Skilled and experienced project teams are at your disposal, ready to transform your requirements into reality LuK technology can be incorporated into your vehicles in a simple, straightforward way. The Black Forest town of Bühl is home to the headquarters of the LuK Group s global automotive supply operations. One in every four new cars around the world rolls off the assembly line fitted with a LuK clutch. LuK products aren t just used in cars, but in commercial vehicles, buses and tractors. LuK s hydraulic applications are also strongly influenced by the factors such as comfort, safety, economy and driving pleasure. Innovative pumps are produced to provide power for steering systems especially on commercial vehicles, and for active suspension and stability control applications. Tandem pumps ensure the necessary injection pressure for fuelefficient engines and ensure a safer supply of energy for the servo function. So, how can we be of service to you in the future? Dr.-Ing. Peter Gutzmer Chairman LuK Group (Board) With 16 worldwide production sites located in Germany, Brazil, Great Britain, India, Mexico, South Africa, Hungary and the USA, we re always closer than you think. Transmission technology has developed into an innovative driving force in the automotive industry. Your expertise and our specialist knowledge enable us to act as a trigger for numerous developments which make the car safer, more comfortable and more economical. Examples of this are the LuK CVT components and LuK s views on twin clutch gearboxes. It is transmission technology which adds considerably to the car s fascination. It is the way in which the car drives that generates enthusiasm and driving pleasure. Enthusiastic drivers are our common goal. 2

Contents Dual Mass Flywheel 4 Clutches 6 Release Systems, Products for Agriculture 8 XSG Family: Gearbox Automation 10 Continuously Variable Transmission 12 Torque Converter, Crankshaft Damper, Belt-Driven Starter Generator 14 Power Steering, Chassis and Transmission Pumps, CO 2 Air Conditioning System 16 Vacuum and Tandem Pumps 18 Awards, Quality, the Environment, Recycling 20 Development Expertise 22 3

LuK Dual Mass Flywheel (DMFW) Damped Vibrations for Undamped Driving Pleasure. Modern engines can be driven at extremely low rpms. The trend is toward ever increasing engine torques. Wind tunnel-optimized bodies are creating less wind noise. New calculation methods are helping reduce vehicle weights and weight-saving concepts are boosting engine efficiency as well. The addition of a fifth or a sixth gear can also reduce fuel consumption. Thinner oils are making precise shifting easier. In short: The sources of noise are increasing and natural damping is decreasing. which are gear rattles and body booms. Drivers who are accustomed to increased comfort no longer accept such background noises. The job of the clutch is now more important than ever in addition to engaging and disengaging, it must effectively isolate the engine s vibrations. Physically, this is easy to solve: The mass moment of inertia of the transmission must be increased without increasing the mass to be shifted. This dampens the engine s torsional vibrations and brings about the desired comfort level. The process reduces load on the transmission at the same time. It s All in the Name LuK was the first manufacturer in Europe to develop and sell a dual mass flywheel in large-scale standard production that was able to realize this physical principle. What has remained is the principle of the piston-stroke engine whose cyclical combustion processes excite torsional vibrations in the drive train the unpleasant consequences of The name says it all: The mass of the conventional flywheel was simply split in two. One part continues to belong to the engine s mass moment of inertia, while the other part now increases Conventional Clutch Dual Mass Flywheel Flywheel with Clutch Clutch Disc with Torsion Damper Primary Flywheel Secundary Flywheel with Clutch Engine Gearbox Speed Fluctuation [1/min] 50 0 50 Time Engine Gearbox Speed Fluctuation [1/min] 50 0 50 Time Torsion Damper Rigid Clutch Disc Engine Gearbox Torsional Fluctuation Measurement in Drive 4

Sounds Good Feels Good These include using multi-stage characteristic curves or friction-optimized lubricants. A clutch disc with a tuned damper helps particularly with rearwheel drive vehicles. The LuK DMFW thus provides a greater degree of comfort in everyday driving operation. the mass moment of inertia of the transmission. The two decoupled masses are linked by a spring/damping system. One clutch disc, without a torsion damper, between the secondary mass and the transmission handles the engaging and disengaging functions. A favorable side effect is that the transmission is easier to shift because of the low mass to be synchronized, and there is less synchronization wear. The use of a very flexible spring between the decoupled masses increases the decoupling level of the transmission even further. The resonance of the system, which must run continuously when starting and shutting off the engine, can also be improved. The optimal use of space of the lubricated arc spring damper used by LuK allows for an especially flexible spring. In addition, it generates a damping characteristic that depends on the effective torque: If there are increased vibrations in the resonance area, the arc spring damper automatically reacts with increased damping. But with small vibrations, such as those that are typical of normal driving operation, only slight damping is generated even at high torques. That is ideal, because in that range, high damping would only deteriorate the decoupling. Various measures can be used to further optimize the arc spring damper for better decoupling depending on the vehicle s requirements. LuK DMFW The Advantages: First-class driving comfort Absorbs vibrations Prevents noise Allows comfortable low-rpm driving Saves fuel Relieves the crankshaft and transmission 5

LuK Clutches 6 The constant trend towards higher engine torque as comfort demands increase simultaneously calls for clutches that on the one hand can transmit very high forces/torques and on the other hand have the lowest possible operating load. The power belongs on the road, not at the pedal. Diaphragm Spring Clutches The invention of the diaphragm spring clutch and its first large series production by LuK was a major development step. The diaphragm spring in the clutch pressure plate generates the required clamp load on the friction facings. Together with the diaphragm spring finger, it also functions as the lever to operate the clutch. Self-Adjusting Clutches (SAC) Since clutches are subject to wear during use in the vehicle, LuK, as the first clutch manufacturer, put a great deal of effort into developing a type of wear compensation system for the clutch, and put it in production in 1995. The self-adjusting clutch (SAC) uses a load sensor (sensor-diaphragm spring) to activate its wear compensation by turning a ramp ring. This compensation mechanism has made it possible to decrease operating loads. Engage and disengage safely and precisely proven a million times over. Force [N] SAC I for Foot Actuation SAC II for Foot Actuation SAC II for Automatic Clutch 2000 1000 conv. Clutch The compensation for the clutch wear has also made it possible to increase the clutch service life by about 1.5 times without any significant change in the operating load over the service life. The wear adjustment system of the SAC consisting of the sensordiaphragm spring (load sensor) and the deep-drawn steel adjuster ring is characterized by very high functional precision. 1 3 5 7 Actuation Travel [mm] Since a harmonic operating load curve is required to ensure a comfortable clutch operation, the SAC was created with the capacity to be tuned to specific vehicle characteristic curves. One of the mechanisms that makes this possible is the compensation spring, which can generate the flatter characteristic curves that are frequently desired. The newly developed SAC II provides a further optimization of the system. Here, the load sensor is not comprised of a second diaphragm spring, but rather of the sensor fingers formed from the main diaphragm spring and special tangential leaf springs with a decreasing characteristic curve. LuK Clutch Discs The clutch disc is the central connecting element of the clutch. Together with the pressure plate, it disengages and engages the engine from and with the drivetrain. One characteristic of every LuK clutch disc is its cushion deflection, tuned to the comfort demands of the customer, allowing a smooth torque build-up during driveaway and an ergonomically tuned pedal effort curve. The speed and torque fluctuations generated by the combustion processes in the engine create noise and wear in the transmission.

Perfection Is Our Strength Clutch Discs with Misalignment Compensation Tolerances in the engine and transmission, especially with transmission input shafts that are not equipped with pilot bearings, cause a misalignment between the crankshaft and the transmission. In extreme cases together with rigid clutch discs for the DMFW, this misalignment can lead to idle noise and increased profile wear. The LuK misalignment compensating clutch disc, which allows for a displacement of the hub in the idle and low-load range, thus compensating for possible radial forces, provides the solution to this problem, thus guaranteeing the function of the DMFW at idle speed even in case of misalignment. To reduce these speed fluctuations, the clutch disc must also perform a damping function. Clutch Discs with Torsion Dampers The clutch disc with torsion damper is the cost- and space-saving solution for torsional vibration problems in the drivetrain. The self-centering conical bush developed by LuK compensates possible misalignment between the engine and transmission and also ensures a precise damper function at idle speed. Clutch Discs without Torsion Dampers Clutch discs without torsion dampers are used in the most efficient torsion damping system in existence, the dual mass flywheel (DMFW). LuK Clutches The Advantages: Excellent operating comfort Long service life Better fuel economy and emission reductions by allowing lower rpms Low-cost, compact solutions through functional integration Dirt- and corrosionresistant Compensation of misalignment between the engine and transmission by clutch discs with misalignment compensation 7

LuK Release Systems, LuK Products for Agriculture Awareness of the latest technological developments allows selection of the best solution. 8 LuK Release Systems system knowledge offers a key advantage. In terms of driving comfort, a driver evaluates the entire clutch and actuation system according to smooth disengagement behaviour, userfriendly force-travel characteristic on the clutch pedal, silent and vibrationfree actuation, together with good modulation behaviour during drive-off and shift processes. The entire system, from pedal to clutch, must function throughout every operating state and guarantee smooth interaction with other vehicle components. Consideration of the entire chain of functionality requires subfunctions in the clutch system to be carefully tuned to each other. When the clutch pedal is activated, the driver senses the system s response. To satisfy requirements on the clutch pedal, clutch system components must be tuned in terms of friction, stiffness and mechanical advantage of the release system. Clutch Master Cylinder LuK supplies clutch master cylinders in an all-plastic design. These are produced with a number of cross-sectional areas and connection geometries (bayonet, flange). Due to the selected combination of piston and seal materials and type of lubricant used, these components remain silent during the actuation process. Pipe Technology Upon request, LuK will undertake both coordination of clutch hydraulic pipe installation and component supply. In addition to the steel/rubber and plastic pipes currently used in production, hydraulic pipe technology is being further developed by LuK in collaboration with our competent partners. Anti Vibration Unit and Peak Torque Limiter Efficient development tools are used to analyse dynamic problems and remedial measures prepared with the help of appropriate simulation models. One result of such a development is the so-called Anti Vibration Unit, a pressure differential valve, which can be used especially to dampen low-frequency vibrations without additional loss of travel, thus eliminating unpleasant pedal vibrations. In the event of the foot slipping suddenly off the clutch pedal, the clutch closes abruptly and high loads occur in the drive train. These can be effectively avoided if the coupling speed is reduced by using a Peak Torque Limiter. This consists of a one way check valve installed in the fluid flow path, which only operates during clutch engagement. Hydraulic Concentric Slave Cylinder (CSC) Hydraulic concentric slave cylinders combine a number of different functions in a compact unit that can be easily mounted to the gearbox. In order to increase the level of functional integration (air bleeding, vibration damping), LuK makes extensive use of plastic materials in the design. To minimise pedal-force, a new lubricant has been developed especially for application in concentric slave cylinders. This guarantees consistent performance throughout the service life. Clutch Slave Cylinder A development comparable to that for the clutch master cylinders has taken place in the use of plastics in the design of external slave cylinders. Similarly to the concentric slave cylinders, it is possible to integrate additional functions. LuK Release Systems The Advantages: High level of vehicle competence Component design using knowledge of the entire clutch and actuation system Minimal vibration, noise and friction Innovative design solutions using plastic materials

The Right Move From The Start Torsion Dampers to Link the Engine and Transmission Combustion processes in the engine create speed and torque fluctuations. These fluctuations cause noise and transmission wear. Torsion dampers are used to reduce these fluctuations. LuK Products for Agriculture It Is Good to Have a Wide Field of Application Options. Farmers all over the world work to feed mankind. The farming machinery industry supplies them with powerful, reliable tools with which to do the job. As a long-time partner of farm machinery manufacturers, LuK makes an important contribution. The one indispensable tool of the farmer is the tractor. Originally nothing but a steel draft animal, it has developed over its hundred-year history into a universal drive machine: a pulling machine for tilling the fields and transportation, a drive machine and carrier for a number of different types of equipment, a provider of mechanical, electrical or hydraulic energy. The operating conditions change from user to user, country to country and continent to continent. Knowledge of the requirements associated with these conditions, careful development of suitable products and production shops on five continents have made LuK the world s market leader in clutches for agricultural equipment. Dry Friction Clutches Dry friction clutches, in the form of single-, double- or multi-disc clutches, are used both in main and auxiliary drives. LuK supplies friction clutches for power output ranges between 20 and 180 kw with diameters from 225 to 360 mm. LuK supplies torsion dampers with linear or curved compression springs. They can be open and run dry or closed and lubricated. They are used in main and auxiliary drives for torque ranges of 100 to 2000 Nm. Release Bearings and Release Systems for Tractor Clutches LuK supplies mechanical and hydraulic release bearings and release systems for agriculture. They are used in conjunction with single- or double-clutches. Other LuK products are also suitable for the agriculture field. LuK Products for Agriculture The Advantages: As a partner to the farming equipment industry, LuK offers Expertise Customized solutions Coverage of the entire performance spectrum 9 A global presence

LuK XSG Family: Gearbox Automation Driving pleasure comes automatically. Without using a clutch or shifting gears. 10 Increasing traffic density means a growing demand for systems to relieve drivers of more routine tasks. Today, auto shift gearboxes and twin clutch gearboxes provide alternatives to conventional automated transmission solutions, offering particular benefits in terms of fuel consumption and dynamic performance. Together, these gearbox variants are known as the XSG Family LuK is developing components for use with the XSG Family. These space-saving, robust units will be available for all kinds of applications in the future. LuK ASG Components Components for the automated shift gearbox, known as the LuK ASG, form the technical basis of the XSG Family: three electric motors perform the movements that the driver would otherwise activate with the clutch pedal and gear lever. The gearbox itself remains unaltered and the required components are both compact and low in weight. For added comfort, a gearbox with LuK ASG components offers the option of manual or automatic gear shifting. In manual operation, gear changing is triggered electronically by touching the gear lever or other controls. In automatic mode, shift points are set by the control unit depending on the driving situation. It is possible to switch between the operating modes at any time and the system also allows any gear shift pattern. The LuK ASG gear control is either integrated in the gearbox or connected to the exterior gearbox control. Clutch actuation occurs via an electro-mechanical drive mechanism, which can move and hold the clutch across the total range of clutch travel. Thanks to a selfadjusting clutch (LuK SAC), clutch actuation is both dynamic and efficient. Due to optimised shifting characteristics, LuK ASG components can reduce fuel consumption compared to a manual gearbox, which can mean savings of more than 10% in the European consumption cycle. LuK PSG Components The PSG is a twin clutch gearbox, consisting of two gearbox units divided into even and odd gears, and a twin clutch. During gear shifting, the torque is transferred smoothly from one clutch to the other. This results in excellent shift comfort comparable with that of a conventional automatic transmission, but with the same low fuel consumption as ASG. Two separate LuK PSG clutch actuators ensure precise control of the twin clutch. Depending on the application, the twin clutches can either be dry or wet (running in oil). Actuation is either electro-mechanical or electrohydraulic. LuK ESG Components Building on the PSG, the LuK ESG components allow a hybrid concept, in which a starter generator is linked to one of the gearbox input shafts. Advantages of the ESG include functions such as start/stop, energy recuperation by regenerative braking and electric powered driving, all with a compact design. Furthermore, with the

Enjoy Relaxed Driving Brushless Motors: Extremely dynamic applications require motor technology which, in addition to low packaging space requirements and high performance, is also characterised by low inertia. Brushless motors offer all these properties, combined with high reliability. Specially optimised brushless motors are being developed for application in the LuK XSG Family components. Modular Actuation: LuK components for the XSG Family can be used for various functions. combustion engine switched off, the airconditioning system can be operated using the electric motor. Depending on the application, the ESG can result in reduced fuel consumption of over 20% compared to a manual gearbox. Technical Highlights of the LuK XSG Components Active Interlock: This new gearbox actuation principle separates the mechanical elements for engagement and disengagement of gears. The shift finger can be moved into the next position while a LuK XSG Family The Advantages: No clutch pedal Comfortable automatic mode Sports manual mode Fuel-saving gear is engaged and the clutch still closed. The old gear is then disengaged and the new one engaged in one single motion, whilst interlocking of gears is ensured in all situations. Shift times are largely independent of which gear change is to be performed. Hence shifting across several gears on automated gearboxes with Active Interlock is almost as fast as a simple gear shift without changing the gear slot. The LuK ASG gear actuator with Active Interlock reduces shift times without adversely affecting comfort and wear. With Active Interlock applied to the LuK PSG gear actuator, only one single unit with two electric motors is needed to actuate both gearbox units. More relaxed driving Low weight Flexible interior design due to shift-by-wire For example, hydrostatic clutch actuation can be used for ASG and PSG applications; and indeed for both wet and dry twin clutches on the PSG. The base unit of the gearbox actuation with a central shift shaft can be used equally for both ASG and PSG. Only the flange and shift shaft are specific to the gearbox. Software Development: In addition to the components, LuK supplies a control software module up to and including the entire system. The entire system's behaviour can be adapted by the vehicle manufacturer for their respective application via a software interface. Particular highlights of the software include slip control and anti-judder control. Both functions ensure lasting, superb driving comfort with LuK clutch actuation. 11

LuK CVT (Continuously Variable Transmission) One Step Further with Continuously Variable Gear Ratios. In 1999 LuK became the first system supplier to introduce CVT components for torque ranges of 300 Nm and above and put them into production. Together with high-performance engines, these components have redefined the concepts of dynamics and comfort with excellent fuel-consumption figures. The CVT Principle Continuously variable gear ratio changing is achieved in the chain CVT, which is suitable for passenger car applications, by varying the axial spacing of the cone-shaped pulleys on the shaft. The chain can run between the two conical pulleys at different radii. The power transmission occurs solely via friction in the steel/steel contact lubricated with oil. LuK Solutions Provide Breakthrough: Two-Stage Hydro-Mechanical Torque Sensor Too little clamping pressure between the cone-shaped pulleys and the chain causes the chain to slip. Too much clamping pressure puts too much load on the components and reduces the efficiency of the system through unnecessarily high friction losses. LuK s twostage hydro-mechanical torque sensor ensures the right clamping pressure for the specific driving situation. The torque is induced using a ramp plate, through which the power flows by means of ball bearings to an axially moveable sensor piston supported by oil pressure. The oil coming from the pump flows out through a variable discharge bore, which ensures constant equilibrium between the axial force of the ball ramps and the compressive force. In the event of a sudden change in torque, the torque sensor temporarily acts as a pump, able to deliver a flow of more than 30 l/min, thus causing a very rapid pressure increase. The LuK Dual-Piston Principle The demands on the hydraulic adjustment system of the variator are very high. Fast controls require high pump power output in conventional CVT systems. The LuK dualpiston principle reduces the volumetric flow required to operate the adjusting cylinder to a third of that required by conventional systems. The hydraulic oil is moved directly from one pulley to the other at high pressure without requiring additional energy. This means that the pump can be designed considerably smaller, which improves the overall transmission efficiency and thus the fuel consumption and performance. LuK Chain Existing chains could not reliably transmit and withstand torques above 200 Nm. LuK has therefore developed a special rocker pin chain, which can transmit torques of up to 400 Nm for high-performance automotive applications. It is constructed of various link plates, which are joined together by the rocker pins of the links. This chain allows a wide gear ratio spread with high torque capacity. Low internal friction losses ensure high transmission efficiency. The combination of the chain and the curved, conical pulleys provides excellent adjustment Primary Pulley Set with LuK Double Piston Secundary Pulley Set with LuK Double Piston 12

Experience Driving Dynamics Again dynamics. In addition, the chain is immune to track offset angle. Enhanced acoustic performance was achieved by computer-aided optimization of the link plate pitch sequence. Compact Hydraulic System The compact hydraulic system, also supplied by LuK, with its direct flange pump, performs all of the control functions required in the transmission. More specifically, these include delivering the oil for the clamping force and variator adjustment, for the start up element and for cooling and lubrication. The compact design, configured for high control pressures of over 60 bar and newly developed control technology, represents the realization of an ideal transmission solution. LuK CVT (Continuously Variable Transmission) The Advantages: Increased driving comfort Smooth transmission ratio changes Low fuel consumption Excellent driving dynamics Compact design/smaller packaging space Fewer components than in stepped transmissions 13

Torque Converter, Crankshaft Damper, Belt-Driven Starter Generator Go Further with Robust Systems and Less Fuel. 14 LuK Torque Converters Advantage through Optimization The torque converter has been used for decades now as a start-up and torque-transmitting device in automatic transmissions. Forecasts show that the torque converter will not be completely squeezed out by alternative concepts in the future if development of the existing converter and gearbox system is continued consistently. Minimizing Slip Since the torque converter s operating principle requires slip in order for it to be able to transfer torque, its operation is always associated with dissipated energy. What would then be ideal is to utilize the advantages of the torque converter for launch and then immediately close the lock-up clutch while driving. In order to prevent noise or vibrations from occurring, LuK sells specially tuned highperformance torque dampers that have been produced in the millions and minimize the existing vibrations through targeted damping and tuning of the spring gradients. Use of a LuK turbine torsion damper, which eliminates special vibration conditions, particularly with a standard drive, can provide an even earlier lock-up with respect to conventional dampers without sacrificing comfort. Controlled Operation with Low Slip Another option for preventing vibrations is controlled operation with low slip. For this approach, LuK supplies innovative friction facing cooling technologies to minimize vibration. These technologies rise above the competition due to their long service life and extreme cooling capacity. These technologies allow for simpler designs while at the same time using inexpensive standard facings. Another positive side effect is a longer life for gear oil, which can be very advantageous with today s high-load transmissions. In the area of NVH reduction, LuK can make use of decades of drivetrain experience with precision simulation techniques, which can significantly shorten project realization times. Optimizing the Fluid Circuit To optimize the fluid circuit, LuK uses 3D flow simulation programs throughout development to make it possible to precisely predict the Torque converter characteristics early on. This also allows for reduced installation space and mass moment of inertia with the same Torque converter performance, or for a more fuel-saving torque converter design with the same installation space, as compared to competitors products. All in all, LuK offers an innovative and flexible, customizable torque converter package for automatic transmissions, which clearly shows that when innovations are implemented logically, performance improvements are still possible even with systems that appear technically exhausted. Internal Crankshaft Damper Reducing Torsional Vibrations on the Crankshaft The natural frequency of the crankshaft is excited when running a combustion engine, due to the gas and inertial forces. This causes the two ends of the crankshaft to twist strongly against one another, which can cause noise and torsional fractures of the crankshaft. To reduce the load on the crankshaft, torsional vibration dampers are generally used today, integrated with the belt pulley of the accessory drive at the free end of the crankshaft. Some next-generation engines will eliminate the belt drive, driving the accessories by other means, but still requiring the torsional vibration damper. LuK s idea was to integrate the dampers into the crank web with LuK Torque Converters The Advantages: High hydrodynamic efficiency Earlier lock-up with an innovative damper Possible use of turbine torsion dampers New, better-performing facing cooling concepts

Expand Your Radius as little effect as possible on the space requirements. The tight space conditions associated with this solution allow only a low moment of inertia for the vibrating masses. A sufficient reduction of the torsional vibrations of the crankshaft is possible only by using steel compression springs whose high energy absorption capacity permits large vibration angles. Belt-Driven Starter Generator (RSG) Now Stop-and-Go Traffic Saves Fuel The use of a starter generator makes comfortable start-stop operation of a combustion engine possible. To do this, it shuts off the engine at standstill and starts it automatically when the gas pedal is pressed again. This start-stop operation of the engine can reduce fuel consumption in the city by about 5%, depending on the engine. The belt-driven starter generator (RSG) is advantageous here because of its simple design. This concept makes it possible to use known and thus proven components and also allows it to be combined with any transmission without any modifications to the drive train. The belt s gear ratio (2.5 3), however, is insufficient for reliable starting of diesel engines and larger gasoline engines, especially at low temperatures. For this reason, LuK has developed a compact two-speed gearbox that allows a higher total gear ratio (e.g. 6 7). The gearbox is integrated within the crankshaft pulley and, in addition to providing the start-up gear ratio, it effectively decouples the accessories from the vibrations of the crankshaft using a free wheel. To drive accessories while the engine is off, the LuK gearbox can be shifted into neutral with a simple actuator. Belt-Driven Starter Generator (RSG) The Advantages: Start-stop operation reduces fuel consumption Lower development expenditures Low system cost No additional weight Favorable installation space requirements Accessory free wheel decouples vibrations Accessories can be driven while engine is off Internal Crankshaft Damper The Advantages: Reduced crankshaft load Reduced engine noise Space advantages Reduced engine mass 15

LuK Power Steering, Chassis and Transmission Pumps, CO 2 Air Conditioning System Totally Calm Even on Tricky Bends. tandem pumps (see page 18). A second vane part could be added for diesel supply or designed as a vacuum pump. Alternatively, a radial piston pump part could supply pressurised oil at up to 200 bar to suspension-struts on chassis systems with anti-roll and pitch suspension adaptation as required. Firm handling when braking and cornering is thus achieved with an otherwise comfortable chassis and suspension set-up. Vane pumps for transmission applications provide pressurised oil for adjusting and controlling automatic transmissions with variable gear ratios, making it possible to always drive with the correct gear ratio, thus saving energy. LuK Power Steering, Chassis and Transmission Pumps In response to consumer demand, the current trends in automotive design are driven towards increased comfort, driving pleasure and improved fuel economy. What is required to reduce steering effort is a light steering control that conveys a precise driving feel. Drivers want a firm, sporty chassis for cornering and braking, but without unnecessary harshness in everyday use.the transmission should shift automatically and conserve energy. Low Pressure Area High Pressure Area Contour Ring Rotor Vane LuK power steering pumps for passenger cars and trucks meet customer requirements for hydraulic power steering systems. The vane pumps are modified and tuned to the operating conditions. By using the energy saving pump LF30EV 2, the pump's energy consumption can be reduced by up to 50%. The power steering pump can be combined with other pumps into LuK Power Steering, Chassis and Transmission Pumps The Advantages: Increased efficiency Low power consumption Compact dimensions Long service life Low noise level 16

Cool And Collected And Safe On The Road The cooling capacity of today s air conditioning systems is limited by the compressor piston displacement. Greater piston displacement is not possible, because there is insufficient space for a suitable compressor in the engine compartment. CO 2 air conditioning systems only need about 13% of the volume flow of an R134a system. This makes it possible to use smaller compressors, which enable the CO 2 system to cool the passenger compartment noticeably faster than today s systems. CO 2 Air Conditioning System Automotive air conditioning systems make a significant contribution both to comfort and passive safety. Studies show that the ability to concentrate decreases significantly at interior temperatures above just 25 C. As with power steering before it, air conditioning will continue in its application all the way to the compact car class in the years to come. Only non-combustible coolants are used for climate control in automotive air conditioning systems. Otherwise, small amounts entering the passenger compartment could become a potential explosion hazard. After R12 was banned over 10 years ago due to its high global warming potential, there is now a grow- ing movement calling for a ban on R134a. Research has unearthed a coolant for use in automotive air conditioning systems that are among the oldest coolants of all: CO 2. In addition to the environmental benefits, the technical advantages of this new coolant have increased in importance over time. CO 2 air conditioning systems consume 20% less fuel than today s systems due to their better average efficiency throughout the year. Because the process is also reversible, unlike today s air conditioners, it also has a heat pump function. This can be used to heat up the vehicle interior very quickly, replacing the electric supplemental heaters Developed in cooporation with Sanden Corporation that are common with modern direct-injection diesel engines. LuK has specialised in the development of coolant compressors and put its pump expertise into practice with the new technology. LuK CO 2 Compressors The Advantages: Excellent cooling performance Excellent control behaviour Drag losses 50% less than with R134a compressors Integrated pressure relief function for the entire system Excellent isentropic efficiency (>75%) Suitable for high maximum pressures and high temperatures Heat pump function possible without major additional expense It is predicted that the clear technical advantages of the CO 2 technology will begin to replace today s conventional air conditioners starting in 2007. The manufacture of the first standard production applications is currently in preparation. 17

LuK Vacuum and Tandem Pumps Good Form and Extremely Durable. Because of the many requirements that modern vehicle engines place on the auxiliaries they run, LuK has exclusively used the rotating vane cell operating principle from the beginning. This concept has spread throughout the world as the only pump design still in use today. LuK Vacuum Pumps LuK s complete redevelopment of the vane cell principle finally led to the use of the world s first single-vane pump in standard production in 1995. This pump, type VAPEC S, is made up of very few individual parts and combines a compact, low-weight size with a high flow rate, low oil flow rate and minimal power consumption. now for larger and heavier vehicles in conjunction with high amplifier volumes. While the use of vacuum pumps was initially limited to diesel engines, today LuK manufactures the latest vacuum pumps for use with gasoline engines with infinitely variable camshaft adjustment or direct injection. Vacuum pumps are made in sizes of 70, 140, 190, 230 and even 270 cm 3, thus covering the entire spectrum of the suction power requirements of modern vehicles, from subcompacts to light commercial trucks. The VAPEC S can expediently provide the higher flow rates required up to LuK Tandem Pumps LuK s outstanding position as a maker of other auxiliary units, such as power steering pumps, fuel pumps and oil pumps, etc., (see page 16) also helps in cases where a solo vacuum pump cannot be installed or would be very expensive to install. Air inlet Oil and air outlet Packaging-Advantages: Extremely compact in axial direction: 26,5 mm (VAPEC 14 S) Air and oil outlet integrated in the centering diameter: advantageous for the cylinder head design Oil inlet Ø 50 g7 Overall length VAPEC 14 S: 26,5 mm VAPEC 19 S: 35,0 mm VAPEC 23 S: 45,0 mm 26,5 VAPEC S-packaging volume 18

An Example Of Power For such cases, LuK offers tandem pumps, which can consist of a combination of a vacuum pump with a power steering pump, fuel pump or other auxiliary units, as a solution. One example of such a tandem pump is the combination of a single-vane vacuum pump with a fuel pre-supply pump manufactured for use with diesel engines with pump nozzle injection technology. LuK Vacuum and Tandem Pumps The Advantages: High suction power to cover the requirements of existing specifications Extremely low power consumption, which contributes in turn to reduced fuel consumption Sturdy construction with high durability and cold-starting ability as well as low idle noise Very small outside dimensions even with high flow rates Outside dimensions can be adjusted to installation conditions Low weight Low engine lubricating oil flow 19

Thinking Ahead. Thinking ahead does not simply mean encompassing innovation and quality for their own sake, but treating the finite resources of our environment carefully and responsibly. Thinking ahead also means recognising that innovation and quality are key elements of a car s fascination and, as such, evoke enthusiasm in motorists. Motivated by Excellence Awards are grounds for both pleasure and motivation. We are particularly pleased that our customers consistently award us for quality, service, technology, price and overall performance. These factors form the basis of the LuK quality policy, which is underpinned by the individual responsibility assigned to every employee. Quality Awareness Quality assurance starts right at the early stages of a project. Following proven planning methods, product requirements are assessed jointly with the customer and any risks minimised via the design process. FE-calculations and prototype programmes support the decision-making process. Internally developed test stations reflect our many years of product experience and guarantee a constant level of quality across all sites. The specialist knowledge of our colleagues in manufacturing equips them to independently approve processes and products. In so doing, they apply the standardised test specifications as required. Extensive process documentation forms a basis for continuous improvement. Our flat decision-making structure means this development is not only rapid, but also benefits our customers. Know-how with a Conscience! LuK employees think ahead. This does not just apply to quality, but also in our responsibility towards the environment. LuK uses the most modern technology and processes for even greater protection of natural resources, reduction of noise, emissions, water usage, waste and scrap. LuK s fundamental environmental principles contribute towards a heightened awareness of responsibility for the environment at all levels throughout the company. 20

This thought process starts during product development. New products should be as effective in saving resources as possible and be capable of being recycled at a later date. The process ends with the collection and recycling of used products. All LuK sites are certified in accordance with ISO 14001. Used clutches from both cars and commercial vehicle have been processed since 1976; since 2001 this also applies to power steering pumps. As such, LuK has shown itself to be a pioneer in this field. Because... It concerns us all! 21

Our most important awards come from enthusiastic motorists. Ideas for tomorrow s automotive world Whilst technological progress is based on knowledge, it is ideas that are behind every product innovation. LuK therefore rates development highly and one sixth of its total workforce is involved in development work. Our attention is focused on customers, their projects and their future vision for tomorrow s automotive world. An individual project team is allocated for each project and will take care of transforming their requirements in a simple and straightforward way. Customer expertise and LuK s specialist knowledge enable us to act as a trigger for numerous developments which make the car safer, more comfortable and more economical. It is also an integral part of LuK s philosophy to constantly offer customers new ideas and suggestions, thus acting as a specialist think-tank. This is how, together with customers, many important chapters have been written in automotive technology history: starting with the first high volume manufacturing of a diaphragm spring through the invention of the dual mass flywheel to the components for the first high-performance CVT, with torque ranges of over 300 Nm and, in power take-off configuration, even up to 500 Nm. And these are just a few examples. We will continue to devote ourselves to backing sound, forward-looking ideas and consistently transforming customers requirements into reality. Robustness and reliability must therefore be key benchmarks of every technical solution. After all, a motorist s fascination with technology is only fuelled by a combination of innovation and reliability. It is this combination which bonds him to his make of car and confirms that he has chosen the right product. It is this which makes the complex and all-encompassing thought process, and hence the development of knowledge synergies so important. Thinking systems that is our benchmark, whether in the field of release systems, where we develop completely new technical solutions through the consistent transformation of the clutch and control system idea, or in the field of CVT. Our work here is not only based on our knowledge of CVT components, but also on the know-how of the combined function of the chain variator, start-up element, hydraulics, software and entire vehicle, as well as LuK specific development and simulation tools. An efficient test rig and laboratory infrastructure is available both for component testing and material research and development. State-of-the-art CAD and FEM programs with internally developed simulation and calculation modules, flexible 22

prototype manufacture supported by extensive measurement and test track activities, together with a sophisticated process development that standardises manufacturing, assembly, test and logistic processes, all combine to ensure that innovations are transformed into products of the highest quality. What can we do for you? 23

LuK GmbH & Co. ohg Industriestrasse 3 D-77815 Bühl/Baden Telephone: +49 7223 941-0 Fax: +49 7223 26950 www.luk.com Subject to change by LuK 2004