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Introduction to Synerject

Introduction to Synerject. Page 1. Customer. Non automotive market : motorcycle, ATV ,scooter, marine, snowmobile, utility. ASDI Technology Engineering Support. Automotive Products and Technology.

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Introduction to Synerject

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  1. Introduction to Synerject Page 1

  2. Customer Non automotive market : motorcycle, ATV ,scooter, marine, snowmobile, utility ASDI Technology Engineering Support Automotive Products and Technology Component production and system integration for two and four strokes direct and port injection system 42% 58%

  3. Asia Europe North America Synerject Synerject Sales Growth Economic Crisis of 2008-09 Fiscal year 2009 (July 1 – June 30) Sales US $81 million Employees (06/30/09) 243 worldwide • Worldwide sales growth 21% p.a. over last four years • Synerject FY’09 sales are up, even as the domestic marine & recreation market is down 30-40% • Diversity and growth in Asia (26% of total business) has cushioned impact of economic crisis in N.A. Worldwide presence 5locations in 4 countries on 3 continents Page 3

  4. Continental market position The on-going integration within the Schaeffler group will bring us to the 1st rank ex-aequo with Bosch

  5. 1997 1998 1999 2000 2001 2002 2005 2004 2003 2006 2007 2008 2009 Synerject History JV established to design and manufacture Fuel Rail Assemblies for the Orbital Combustion DI system on Motor Scooter and Marine & Rec vehicles Company expanded to include Engine Management Systems for Port-Injected Two-Wheel vehicles Company expanded to include all of Siemens VDO EMS for non-automotive and EMS for Marine, Snowmobile, and ATV Company acquired low-volume high-end Electronics facility in Delavan Wisconsin USA Established Production and Applications Center in China Production launch M3A module in Changchun China Synerject change of control Page 7

  6. M3: SYNERJECT EMS non automotive family Segment D 4 cylinders M3D Standalone case “D” Drive by wire Torque structure 96 pins IPX9 (Marine) Segment C 3 cylinders Segment B M3C Standalone case “C” 48 pins IP67 2 cylinders Segment A M3B Standalone case B” 32 pins IP67 M3A Integrated Air module 32 Pins IP67 1 cylinder High end motorcycles & recreational applications 4S scooters & light motorcycles Middle range motorcycles Low end recreational applications 4S&2S DI scooters & ATV & motorcycles

  7. High integration Simplicity of use Robustness Flexibility Cost optimization Throttle Body Air bypass valve (option) Throttle position sensor Plastic housing ECU with Pressure & Air temperature sensor M3A family Integrated Air Module 4 stroke scooters & light motorcycles In production since 2007 • Main parts • Aluminum Throttle Body • Plastic enclosure • Electronic board • Embedded components • Pressure sensor • Air temperature sensor • Air Bypass valve • Throttle Position Sensor • Environment • IP 66 • IP x9k (high pressure cleaning) • Operating temperature from -20°C to +85°C • Vibration level : 20 g • EMC according ISO 11452 & ISO 7637 Page 12

  8. M3AFlexibility M3A • Displacements from 50cc to 250 cc • Same plastic housing • Same PCB • Different Throttle Bodies 250 cc 30 to 34 mm 125 cc 26 to 29 mm 50 cc 16 to 21 mm Page 13

  9. M3Aelectronic architecture • Faster and more accurate than competition • 16 bit, 16 Megahertz • 128k of Flashprom • Possibility to go up to 24 Megahertz and 256k • Higher number of input/output with Option available for geared motorcycle • Adapted to future M/C electronic architecture • M3A is K and CAN to interface with vehicle functions (e.g. Instrument cluster information,ABS, keyless starting systems) Page 14

  10. M3A Applications at KYMCO • G5 125cc • G5 150cc • Racing 125cc • Racing 150cc • VJR 100cc • JR2 100cc • Kiwi 100cc • Cherry 100cc • V1 125cc • 50cc 3V

  11. Applications at SYM (Sanyang) • Fighter 125cc • Fighter 150cc • Fortune 125cc • Fortune 150cc • GT125cc • X-Pro 125cc • Wowow 100cc • Wolf 125cc • Wolf 150cc • RV 180cc

  12. Other Applications • Other customers in production and under development: • Peugeot • GLR • Modenas • Qingqi • Jialing • Applications: • 100cc scooter • 120cc motorcycle • 125cc scooter (2 customers) • 150cc motorcycle • 190cc scooter • 250cc motorcycle (2 customers) • 250cc scooter • Some motorcycles use M3A Standalone version

  13. M3C family • Polyvalence • Robustness • Flexibility • Performance • Cost efficiency Middle range motorcycles Low end recreational applications In production since 2007 • Robust mechanics, based on: • Watertight Automotive connector • Aluminum case • Crimped cover • Environment • IP 67 • IP x9k (high pressure cleaning) • Operating temperature from -40°C to +85°C • vibration level : 20 g • EMC according ISO 11452 & ISO 7637 • Perimeter • Single and twin cylinder 4 strokes engines, • Suitable for all non-marine applications, including Motorcycle, ATV and Snowmobile, • Adapted to all coming emission regulations in Europe and in North America, Page 18

  14. M3CElectronic architecture • 1) FASTER & MORE ACCURATE • 16 bit, 25 Megahertz • 256 k of Flashprom • Enhanced timer module for increased control capability • Possibility to go up to 40Megahertz and 512k • 2)Enhanced functionality: • Knock detection, • Stepper driver for ABV control • 16 power outputs / 16 inputs • M3C is providing CAN communications for interfacing with vehicle functions (e.g. Instrument cluster information,ABS, keyless starting systems) • Quick reprogramming thanks to CAN Page 19

  15. M3CSpecific functions for motorcycles and recreational • Increment evaluation for a 36 – 2 & 24-2 teeth wheel for a smaller package • for highest engine speed (up to 16.000 rpm) • for extremely high rpm-gradients (up to 19.000 rpm/sec) • Injection/ignition determination for V-engines with asymmetrically TDC • Cylinder selective • load determination • ignition angle application • fuel mass application • Alpha/ n and p/n - system with enhanced control of the transition • Control with short and long term adaption • Injection with two injectors per cylinder and variable fuel sharing • Specific manifold pressure calculation • minimal pressure detection (engine w/o plenum chamber) • Engine speed / torque reduction to support clutchless shifting Page 20

  16. M3C Applications

  17. M3D family • Ready to use • Automotive quality & technology • Performance • Model torque based • Last technology • Best value High end motorcycles & recreational applications First SOP August 2009 • Software • SYNERJECT generic engine control strategy for 1 to 4 cylinders engine based on true torque structure • Safety concept functions complying to automotive safety requirements + motorcycle safety concept in cooperation with OEMs • Housing • Minimized size: 123x139x39mm • Bottom plate: metal shield • Cover plate: aluminum die cast • Environmental Conditions • Suitable for passenger and engine compartment (no direct engine mounting) • Tightness class: IP6K9K, IP67 • Operating temperature: -40°C ..... +85°C (ambient air temperature) • Vibration class: 10g Page 22

  18. M3DElectronic architecture • µController Freescale 32bit µCore (MPC55xx) • 40 MHz, 32 kB RAM, 768 kB Flash, 2kB E2PROM emul. • Separate monitoring unit for ETC systems • Chipset • Optimized by high integration • New System-Chip to group several electronic functions • Minimized size & reduced costs • Interfaces • 1 CAN interface with 500 kBaud • 1 K-line Interface

  19. Electronic Throttle Control • Based on the 18-y experience of Continental, Synerject is currently developing customized multi-blades Electronic Throttle Control. • Those customized products reuse generic modules (components and manufacturing) based on the latest generation of Continental portfolio for AUTOMOTIVE PRODUCT • When applicable (single cylinder) we are also delivering from the shelves components • Main characteristics (ETC 8 diameter 44mm) • Drive: DC-motor M36 with two-step gear • Sensor: highly integrated MR sensor system (ASIC) • Housing: Aluminum • Throttle plate: Plastic • Connector: 6-pole, different variants • Temperature range: -40°C to +140°C • Response time:  100 ms (full stroke, RT) • Default position: flexible to project specific demands • Leakage: differential pressure 600 hPa, TP- 44 mm: < 2,0 kg/h *

  20. Family of ECU Number of Number of Number of Application Picture OEM Customers Micro- Product Application injection Pins Cylinders Engine Type Controller >15 BAJAJ, KYMCO, SYM, PEUGEOT, ENVIROFIT 8-bit Scooter ASDI & PI 22 single cylinder (50cc to 1-2 M2 250cc) KYMCO, SYM, PEUGEOT, GLR, QINGQI, MODENAS, JIALING >30 Scooter, M3A 16-bit 1 PI single cylinder (50cc to 31 motorcycle 250cc) >20 DUCATI, ROTAX, ARCTIC CAT, TGB, DINLI single and twin (400cc 48 M3C 1-2 Recreation PI 16-bit up to 1100cc) >10 Motorcycle, ROTAX BRP 1-3 single to triple (2s- PI Marine, ATV, MSE 3.7 2 x 41 = 82 16-bit 500cc up to 4s-1600cc) snowmobile BRP JOHNSON EVINRUDE E-TEC 16-bit >10 2-6 Marine outboard DI EMM 76-89 (2S-500cc to 3000cc) MERCURY WOODWARD GOVERNOR Marine outboard and Inboard >10 48 32-bit ECM 4-8 PI (2S-500cc to 3000cc) MERCURY WOODWARD GOVERNOR >10 Marine outboard and Inboard 80 32-bit PCM 3-8 ASDI & PI (Up to 8.1L) >5 (in development) Recreation and WEBER DUCATI 1-4 (twin to 4-cyl, 500cc to Marine, all ETC 96 32-bit M3D PI 1600cc) Applications

  21. M3L • OBJECTIVES: • Improve the performances and the functionalities of a 125cc Motorcycle mechanical gearbox thanks to an ultra low cost EFI system • Replace the carburetor and CDI system with minor modifications on vehicle • IMPROVEMENTS TARGETS: • Base: 100ppm system quality in the plant/ in the field, low emission, good start ability cold and hot with kick start, drivability during warm-up, good operation up to 3000m, lower fuel consumption, idle speed stability • Option: battery-less, automatic air choke, immobilizer • M3L DESCRIPTION: • Based on M3A: control functions, electronic, calibration tools, communication SW • Size reduction of 40%: electronic, electrical connector, throttle body length (id to a carburetor), fuel pump and regulator • Interfaces: same as a carburetor for the throttle body, the fuel pump and regulator replaces the fuel tap at the bottom of the fuel tank, the fuel injector is mounted on the throttle body • New advanced control functions that eliminate throttle position sensor and cylinder head temperature sensor (tbc)

  22. M3L= Air module + Fuel delivery module in line + PRELIMINARY DESIGN • Throttle body • Injector & fuel cap • ECU with sensors • Fuel pump 5l/h, flow control • Fuel pressure regulator • Filter

  23. Fuel delivery in line • Main characteristics: 5l/h, up to 3b • Low weight, low size • Brushless • Mechanical interface with the fuel tank same as the fuel tap of carburetor • Controled by the ECU without relay • Fuel flow control: low electrical energy demand, < 1W at idle • Returnless • E15 compatible <30mm <40mm

  24. - + IGN _ F F INJ _ V B K Key Switch F Fuel Pump 1 A < M 3 L TPS VBK () IGN _ 1 ( HP ) HEGO _ S ( AN ) INJ ( 1 . 7 A ) spare _ In ( optional ) + FP ( 2 . 5 A ) Ua LSD 1 ( optional ) O 2 S MAP _ SGND ( optional ) TIA Reprog / Reprog / MIL K _ LINE ( COM ) IMMO IMMO Tool Tool TAM CPS _ P ( B 2 ) CPS _ M ( B 1 ) PGND () Minimal system, connector 12pins • Main functions: injection, ignition, optimal performances in full application range • Replacement of the carburetor with minimal modification: wiring harness • Air choke on TB as for carburetor or automatic (option) • O2 sensor if stringent emission and better durability are requested • Configuration: immobilizer, 3 customized pins (inputs or outputs)

  25. M3L, minimal system, more details 12pins PRELIMINARY DESIGN 80mm 50mm (Variant)

  26. M3L TIMING • SOP : first quarter 2012 • PPAP end 2011 • C sample: third quarter 2011 • Design freeze: second quarter 2011 • B sample end 2010 • Concept freeze: September 2010 • Customers requirements freeze July 2010

  27. FUEL Fuel Pump Fuel Injector Direct Injector Fuel Pressure Regulator Inside Fuel Rail Ignition Coil ECU Air Compressor ASDI system • Specific ASDI BOM: • M2 ECU or M3C with external driver • Air and fuel injector • Specific Fuel Rail Mounted on cylinder head • Piston fuel pump • Air compressor • classic sensors & actuators • Advantages • Proven system on small and large engine • Perfect mixture preparation • Disadvantages • System complexity and relative cost

  28. Fuel Metering Event Air Injection Event * Ignition o o o 360 180 0 TDC TDC TDC Fuel metering and Air injection event not linked Direct Injection Technology Fuel Air MPI fuel injector Air injector Direct injected premixed charge

  29. Fuel Pump DI FRA Air Injector Fuel pressure regulator PI injector Air Hose Assembly DI/PI Fuel system for high specific power engine

  30. ECU 1 2 Side injection system Fuel-pressure Regulator Fuel Pump Ignition Coil Engine Temperatur Sensor TPS ….Air Temp. Sensor 1 2 ....Air Pressure Sensur Throttle Body Crankshaft Position Sensor Oil tank Oil Pump Fuel Injector • Advantages • System reusing automotive components (except Fuel Pump) • Cost • Proven and available for 50cc • Disadvantages • Need to be set-up for larger displacement • Specific BOM: • M3A or M3C ECU • Fuel injector • Piston fuel pump • classic sensors and actuators

  31. PI 4 Stroke systems

  32. CONTENTS SYNERJECT HISTORY PRODUCTS & SERVICES ECUs and SYSTEMS COMPONENTS CUSTOMERS LOCATIONS Page 37

  33. Engine Management Components Electronic Control Units Fuel and Air Modules Electronic Oil Pumps Direct Injectors D.I. and P.I. Fuel Rails Fuel Injectors Pressure Regulators Sensors In-Tank Fuel Pumps

  34. aSDI Piston Fuel Pump (small scooter applications) Fuel Pumps and Fuel Delivery Modules Intank Electric Fuel Pumps (motorcycle, ATV, snowmobile applications) Fuel Delivery Module with Internal Jet Pump (Snowmobile Application) Fuel Delivery Module with Automotive Level Sender (typical motorcycle, ATV application) • Conductive plastics • Return or Returnless Systems • With/Without System Fuel Filter • With/Without Pressure Regulator

  35. Injectors & Fuel Rails 4 Stroke Port Injection Single & Twin Cylinder Rails (motorcycle & ATV engines) Port Fuel Injectors (all application types) Fuel Hose Assemblies (all application types) Inline 4 Stroke Port Injection Fuel Rail Assembly (inboard marine engine) 2 Stroke Direct Injection Fuel Rail Assembly (outboard marine engine) Direct Injectors (marine, motorcycle and ATV applications)

  36. Spark plug position symmetrical recirculation area Direct Injection Solenoid High Pressure Direct Injection Used for cylinder wall air guided applications Continental in production since 1999 and the 1st EU supplier Piezo High Pressure Direct Injection Used for central spray guided applications Continental automotive production since 2005 Orbital Air Assist Direct Injection Used for central spray guided applications Synerject in production since 1997 Benefits of Direct Injection Improved low end torque when used in turbo charged applications Improved fuel economy Improved emissions Page 41

  37. Plastic Body, Tank Mounted (Snowmobile Applications) Aluminum Body, Flange Mounted (Outboard Marine Applications) Plastic Body, Tank Mounted, with Hoses and Harness (Outboard Marine Applications) Electronic Oil Pumps • 2-Stroke Applications • Multiple ports with individual outputs tailored to customer needs • 1, 4, 7, 9 ports in production today with other numbers possible

  38. Megatrend EnvironmentThe Way to Zero Emissions EV (Electric Motor) Emission free electric vehicles (EV) (long term) Back up combustion engine by electric motor (mid term) Improve efficiency of conventional powertrain (short and mid term) 3 ZERO EMISSIONS 2 1 Fossil Fuels Renewable Fuels 100 % Combustion Vehicle(Combustion Engine) 1 Hybrid Vehicle (Combustion Engine + Electric Motor) Vehicle Production 2 3 0 % TIME Electricity from Power Grid

  39. “Zero Emission” – Powertrain’s Goal Make driving affordable, powerful and smooth with reduced emissions and fuel consumption Powertrain System Optimization of powertrain efficiency from tank to tail by system integration of components and functions Innovative components and software/functions for the entire powertrain of gasoline, diesel and hybrid engines using conventional and renewable fuels Powertrain Business Units

  40. Non automotive Powertrain key technologies Fuel Supply/Air Exhaust Aftertreatment Charging Transmission Hybrid / EV Starter-alternator Stop & Go Regen @ braking Torque assistance Optimization of powertrain efficiency: system integration of components and functions Electrical architecture • Fuel delivery module • Fuel supply • Fuel vapor management • Electronic throttle control • Smart MTB Battery less Electrical power management Fusing & relay Control Systems • EMS- TMS • Hybrid Supervisor • Control algorithms • OBD- Maintenance • Safety engine & vehicle • Intersystems: immo, dash.. Combustion Systems Lambda close loop Catalyst light off function • 2S/ 4S Direct injection • 2S ATAC/ CAI • VVT • Intake flap • Exhaust flap • Knock control • EGR Turbocharger Supercharger Impulse charger Electronic CVT Robotized gearbox

  41. SYNERJECT System roadmap generic platforms 2014 2&4-stroke HPDI 2012 Electrical Urban Robotized gearbox Electronic CVT Urban Hybrid 2010 M4A Fuel delivery module M3B 4S PI&2S_DI 2008 M3D (4-stroke) DBW M3L (4S) M3C (4-Stroke) M3A (4S)

  42. CONTENTS SYNERJECT HISTORY PRODUCTS & SERVICES ECUs and SYSTEMS COMPONENTS CUSTOMERS LOCATIONS Page 48

  43. Synerject’s Customers

  44. CONTENTS SYNERJECT HISTORY PRODUCTS & SERVICES ECUs and SYSTEMS COMPONENTS CUSTOMERS LOCATIONS Page 50

  45. Toulouse France Synerject Locations Synerject Newport News August 2000 Synerject Changchun October 2006 Synerject Toulouse July 2005 Delavan Wisconsin USA Changchun China Chongqing China Newport News Virginia USA Pisa Italy Taipei Taiwan Synerject Delavan March 2006 March 2007 Synerject Locations Synerject Chongqing Regional Customer Support

  46. ISO 9001 Certified Since 2003 Synerject Newport News Newport News, Virginia USA • Synerject Facility Since August 2000 • Synerject Company Headquarters • 60,000 square feet • 50 employees • EMS Applications for North America • Chassis and Small Engine Dynamometer • Fuel Systems, Modules, & Components Product Engineering • Fuel, Air, Gaseous Injectors • Fuel Rails and Hoses • Oil Pumps • Fuel Pump Modules • Air Modules • Production of EMS Modules and Components • Air Injectors • Fuel Rail Assemblies • Oil Pump Assemblies • Fuel Pump Module Assemblies • Certified ISO 9001:2000 • Engineering and Test Center • Full Design and Product Validation Testing

  47. ISO 9001 Certified Since 1999 Delavan Delavan, Wisconsin USA • Synerject since March 2006 • 40,000 square feet • 90 employees • Electronics Design • Electronic & Mechanical Assembly and Test • Electronic Control Units • ETEC EMM • M2 ECU • ETEC Fuel Injector Assemblies • ETEC Oil Pump Assemblies • Located in the Heart of the North American Marine & Recreation Industry

  48. ISO 9001 Certified Since 2006 Toulouse, France • Established in Toulouse July 2001 • Synerject Europe Headquarters • 5,000 square feet • Total headcount : 29 • Engineering headcount :18 • Engineering location to support EMS application • Customer systems applications • EMS design and engineering • Software Engineering • Procurement & logistics • Sales to Europe and Taiwan customer

  49. Changchun CHINA Chongqing M3A Module Synerject China • Production located inside Continental Automotive Changchun facility • 4,000 allocated square feet • Synerject SOP in September 2007 • Certified TS 16949 quality • Production of : M3A module • Headcount: 24 • Synerject Sales and Application Engineering Center - Chongqing • Regional business development and customer sales support • EMS system integration and customer application support • Headcount: 9 Synerject Changchun Synerject Chongqing

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