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Heavy Duty Electronics & MechatronicsGlobal Market Perspective
© 2009 WABCO Holdings Inc. All rights reserved.
Joe KripliGlobal Business Development WABCO Reman Solutions
APRA Heavy Duty Remanufacturing Group SummitLas Vegas, Nevada - January 21, 2013
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Sales of $2.8 BILLION in 2011
A GLOBAL TECHNOLOGY LEADER serving the commercial vehicle industry, specializing in Air Braking and related systems
Over 10,000 EMPLOYEES in 31 countries
18 MANUFACTURING LOCATIONS in 10 countries
Listed on NYSE with the stock symbol WBC
ABOUT WABCO
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MANUFACTURING & REMAN LOCATIONS
Rochester Hills
Stanowice
Jinan
Global Presence
MexicoSan Luis Potosi*
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MANUFACTURING & REMAN LOCATIONS
Rochester Hills
Stanowice
Jinan
Global Presence
MexicoSan Luis Potosi*
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TRUCK AND TRAILER PRODUCTS TRUCK
Electronic Control UnitsAdaptive Cruise ControlEBS Proportional Relay ValvePedal Unit with EBS Brake Signal TransmitterABS Modulator ValveAutomatic Temperature ControlElectronically Controlled Air SuspensionShock AbsorberFront Air Disc BrakeSteering Angle SensorTransmission AutomationClutch ControlRetarder ControlAir CompressorRear Air Disc Brake(Electronic-) Air Processing Unit ReservoirEBS Trailer Control ValveElectronic Stability Control ModuleEBS Axle Modulator
TRUCK AND TRAILERBrake ChamberTristop® CylinderAir BellowIntegrated Vehicle Tire Monitoring ECUIVTM Wheel ModuleDouble Diaphragm Spring Brake
TRAILERTrailer Central ElectronicSmartBoardTrailer Electronic Braking SystemElectronically Controlled Air SuspensionTrailer Air Disc Brake
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EBS: Electronic Braking System
ABS: Anti-Lock Braking System
ECU: Electronic Control Unit
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BUS PRODUCTSEBS Brake Signal TransmitterEBS Proportional Relay ValveABS Solenoid Modular ValveElectronic Stability Control UnitEBS Backup ValveEBS Axle ModulatorAdaptive Cruise Control ModuleHand Brake ValveIVTM DisplayIVTM Wheel ModuleIVTM Electronic Control UnitAutomatic Traction Control Water ValveATC Operating ConsoleATC SubstationElectronic Control Units EBS, CVCECAS Electronic Control Unit ECAS Solenoid valveECAS Level SensorAir Disc BrakeBrake ChamberTristop Cylinder(Electronic) Air Processing UnitCompressorMTS SensorMTS Door CylinderMTS Electronic Control UnitMTS Door Valve
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1011121314151617181920
EBS: Electronic Braking System
ABS: Anti-Lock Braking System
CVC: Central Vehicle Controller
IVTM: Integrated Vehicle Tire Monitoring
ECAS: Electronically Controlled Air Suspension
MTS: Door Control for Bus
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Heavy Duty Technology led by EU Legislation driven by SAFETY AND ENVIRONMENT
Fuel Efficiency
Emission reduction
Energy recovery
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GLOBAL LEGISLATION OVERVIEW2010 2011 2012 2013 2014 2015
ESCRSS
(Turkey 2013)
LDWSAEBS
(Turkey 2015)
Shorter stoppingdistances
Euro IIIemission
ESC for HCVsFuel efficiency
ABS - trucks, busses & trailers
MandatoryABS
Euro Vemission
Euro Vemission
Euro III & fame emission
ECE Reg 13 LDWS - AEBS Fuel efficiency
ESC = Electronic Stability ControlLDWS = Lane Departure Warning SystemAEBS = Advanced Emergency Braking Systems
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The cause for Mechatronic Evolution in light duty truck and passenger car market Government regulation
– Tighter emission standards– Increased safety
requirements – Increased CAFE fuel
economy standards– Recycling Requirements
TECHNOLOGY EXPLOSION - Traditional mechanical systems are being replaced by electronic and mechatronic systems
TECHNOLOGY EXPLOSION - Traditional mechanical systems are being replaced by electronic and mechatronic systems
Technology Impact– Increased number of electronic
modules (ECM, BCM, TCM, Safety, Security, etc.)
– Increased engine performance (direct Injection, turbocharging, diesel)
– Driver convenience products increases(bluetooth, navigation, web‐enabled, video)
– Complicated system integration (CAN network)
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HD industry is following the same path• Government regulation impact
– Emission Reduction• Selective Catalyst Reduction (SCR)• Exhaust Gas Recirculation (EGR) solutions to reduce emissions
– Safety Improvements• ABS/Stability Control
– Recycling Requirements
• Fuel economy improvements– Common Rail Diesel injection systems– Hybrid Powertrain (buses, delivery trucks)– Alternate fuels (fuel cells)
• Technology Impact– Increased engine performance– Driver convenience products increases (Automated transmissions)– Systems converting to “by wire” systems replacing pure mechanical
Traditional mechanical systems are being replace “BY WIRE” electronic and mechatronic systems
Traditional mechanical systems are being replace “BY WIRE” electronic and mechatronic systems
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Technology Impact on the Industry?
• New diagnostic & training requirements at the repair level– System integration of multiple electronic products– CAAN communication
• Flashing/Software update requirements• Life cycle production concerns
– Past model electronic component shortages– Life time buy requirements (how do you know how many you need?)
• Core handling changes – Cannot damage connector or case– Cannot damage electronic components– Electro‐Static Discharge (ESD) concerns
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GLOBAL TRUCK & BUS PRODUCTION(over 6 tonnes Gross Vehicle Weight)
India
Total 2,732K units
Total 2,088K units
China
Japan/Korea
S. America
N. America
Europe
Total 2,998K units
2008 2009 2010 .
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GLOBALIZATION: INDIASALES PROJECTIONSIndexed (2010 Sales = 100)
100
152
225
2010 2013 2015
Strongly anchored market leader
Preferred supplier for all OEMs
Nationwide sales and service network
Extensive product & software development capabilities
Lean and Six Sigma driven manufacturing
High record of industry awards
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GLOBALIZATION: CHINASALES PROJECTIONSIndexed (2010 Sales = 100)
100
214
325
2010 2013 2015
CAGR 27%
2005 to 2008 sales grew at 70% CAGR
Signed long term agreement with CNHTC through 2016 including sole supplier of transmission automation systems
Joint venture with Fuwa, world’s largest maker of trailer axles, to produce air disc brakes in China
Growing presence in WABCO’s global manufacturing network and an internal benchmark for Six Sigma Lean
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Mandatory in EU in Nov. 2011
Includes yaw control to keep vehicle on steered course and avoid jack-knifing
Roll Stability Support mitigates roll-over situations for coaches, trucks and trailers
ESCsmart™: Industry’s first technology that uses computational simulation to certify ESC. Breakthrough homologation system approved in 27-country EU and in 20 other countries
INNOVATION: ELECTRONIC STABILITY CONTROL
SALES PROJECTIONSIndexed (2010 Sales = 100)
100
581
857
2010 2013 2015
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An opportunity for the HD Reman Industry
• Substantial Mechatronic and Electronic content per vehicle
• Sustainable Life Cycle Model– Provide service parts for 15‐25 years– More affordable replacement parts
• Need to develop electronic testing and repair capabilities
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“We can't solve problems by usingthe same kind of thinking we used
when we created them.”‐‐ Albert Einstein
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DESIGN FOR REMANUFACTURING
• Allow for easy disassembly of product
– Screws preferred
– Minimize rivets
– Alternative to Tyco “Action Pin” connections for circuit boards?
– Alternative to plastic tabs fasteners for TEBS‐E ECU case?
• Consider wear out electronic components easy access (i.e.
top side of circuit board) and replaceable.
• Need to diagnose ECU failures
• Need to be able to reflash software to latest version.
19Source: Dekra Verkehrssicherheitsreport LKW 2009, May 2009
POSSIBLE MITIGATION SYSTEMS
LDW
ACC
BSD
ADVANCED SAFETY: MOST FREQUENT ACCIDENTS
Stability Control System
Lane Departure Warning
Collision Mitigation System
Collision Mitigation System
Autonomous Emergency Braking Systems
Autonomous Emergency Brake
Passive under run protection
Advanced mirrors
Blind Spot Detection
Advanced Emergency Braking Systems
Autonomous Emergency Braking Systems
Advanced Emergency Braking Systems
Advanced Emergency Braking Systems
Moving/stopping objects
Stationary objects
Adaptive Cruise Control
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Key Milestones
Initiation Phase
SOP
Production Launch
Process ValidationPhase
Process DesignPhase
Concept/QuotationPhase
IndustrializationPhase
P1P1 P2P2 P3P3 P4P4 P5P5
Mar 23, 12
Dec 1, 11
April 13, 12May 11, 12
May 31, 12
Jun 18, 12
Jun 22, 12Jun 22, 12
Planned Key Milestones
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Exhaust gas recirculation
Mechatronic Control Unitsfor emission and turbocharger
controls
SCR Air & Coolant ControlEngine Brake
Actuation
VEHICLE EFFICIENCY ROADMAP
Fuel Efficiency
Emission reduction
OptiDrive AMT
Retarder Control
Hybrid Controls
Energy recovery
Engine Control
TransmissionControl Brake Control
VCM
J1939
Blue: controlled by WABCO today
Hybrid
AEBS
Retarder Compressor
Friction Brake Trailer Brake
Engine BrakePowertrain (incl. AMT)
El. Drive Regen.
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280 369499 471
621515 600
836 8741,033
1,487
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
CHINA: AN ONGOING PHENOMENON
280 369 499 471621 515 600
836 8741,033
1,487
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
9.9 11.0 12.0 13.6 16.018.4
21.225.7
30.133.5
37.0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Unit: Trillion RMB
Unit: ‘000
855534Highway (K KM)
300230187Road (M KM)202020102004
CHINA T&B PRODUCTION GVW > 6T
CHINA GDP Road/Highway Plan