Clutch Systems. Innovative Solutions for All Roads

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4 P r o d u c t i o n Gearing up for Tomorrow LuK supplies components and systems for vehicle drivetrains around the world. When Georg and Wilhelm Schaeffler founded LuK in 1965, their objective was to produce clutch cover with diaphragm spring systems for the successor of the VW Beetle. Today, LuK clutches are used in one in four cars worldwide. With innovative products and lean, customer-oriented structures, LuK is experiencing highly dynamic growth. Almost all major automobile manufacturers benefit from the knowledge of LuK engineers. Dedicated employees, innovation, product development and technological leadership are the main factors of the company's success. LuK makes project teams available to all its customers to ensure that specific requirements are met. As a technology leader in many areas, LuK can look back on a legacy of having developed many groundbreaking innovations. In 1965, LuK was the first company in Europe to market a diaphragm spring clutch. Twenty years later, LuK launched the first dual-mass flywheel. This was followed by the introduction of components for CVTs that could handle more than 300 Nm of torque, as well as Auto Shift Gearbox (ASG)- the world's first electromagneticallyautomated manual gearbox. In 1997, LuK began engineering and manufacturing torque converters in the US; Germany followed in LuK's current R&D efforts, in addition to the continued development of conventional transmission systems, have a particular focus on alternative drivetrain concepts, such as components for dual-clutch transmissions and hybrid drivetrains. LuK is also an important supplier of many other products, such as hydraulic cylinders. OEM and Agricultural Business focuses on new developments and stands for excellence in supply to manufacturers. The Aftermarket business unit, created by LuK, is currently responsible for the entire automotive aftermarket business of the Schaeffler Group, and supplies a large variety of products of the INA, FAG and LuK brands - about 20 thousand different items of original replacement parts, moreover remanufactured products. The company offers comprehensive services to distributors, wholesalers, repair shops and exclusive car dealers, including a strong technical assistance program. Machining Stamping Heat Treatment Clutch Assembly Clutch Release System Assembly

5 P r o d u c t s a n d S e r v i c e s 1. Engine Flywheel Technology reference in trial technology and Dual Mass Flywheels (DMF) supplies analysis and expert reports The current development on for all other operations of the LuK internal combustion engines lead Group. the new projects for systems, which operates at lower rotations, higher 3. Conventional and Self-Adjusting compression rates and less mass. Clutches (SAC) New eco-friendly fuels change the The trend of increasing the engine systems torsional features. torques and the growing demands Vehicles are constantly optimized on comfort require clutches capable by reduction of running and wind to transmit a high torque on one noises. As a consequence, internal hand, but featuring low operation noise sources are increasing and power on the other hand. The system dampers diminishing. As diaphragm spring development was per the theories of physics, the the first step taken by LuK to meet solution is to increment the such demands. Where as a clutch is transmission inertial mass, without a wearing component in vehicles, increasing the coupling system LuK has been investing great efforts inertial mass. Thus, the rotation to continuously develop and responsible for the system excitation and which provokes a reso- minimize those wear effects. In improve compensation systems to nance, reduces below the idling 1995, LuK started the production of shift speed. the self-adjusting clutch (SAC), which uses a system based on a 2. Centrifugal Burst Trial of load sensor to actuate the wear Cylindrical Parts. compensation system and, consequently, the effort on the clutch Searching for quality excellence and perfection in product durability, LuK pedal. has developed proceeding trials and Besides the clutch cover, the disc test rigs for the accelerated plays an important role in the evaluation of centrifugal and coupling between engine and centripetal forces on complex transmission. As core element of cylindrical components and this connection, LuK has specialized products, thus allowing the itself in tuning of axial characteristics system, which provides modula- continuous improvement of our projects and the projects of our tion and clutch pedal actuation partners and customers. In our R&D comfort. Center in Sorocaba we are able to As secondary function, but not less perform component trials, such as important, clutch discs of modern engine flywheel systems, clutches developments allow the implementation of torsional dampers in its and brake discs at high safety and reliability levels. With local knowledge and expertise, the R&D Center vibrations produced by the internal core part, which dampen the in Sorocaba has become a world combustion engines, improving the 1 2 users comfort and avoiding the premature wear of the transmission gears. LuK clutches provide excellent operating comfort, long operating life, compact solutions by means of function integration, strength and misaligning compensation between the engine and the transmission. 4. Virtual Development Already during the first development, LuK applies the virtual development concept on its projects, anticipating the products' final behavior, even before the first physical prototype. By means of computer methods, such as virtual analysis and simulations to optimize the project, the research cycles of the vehicle components are reduced. In other words, LuK anticipates the definitions involving the development of geometry and shapes, durability, vibrations and noises, temperature distribution in operation conditions, as well as manufacturing process details. 5. Vehicle Testing Technology Sustained by LuK's values, the Experimental Engineering Department is composed of a specialized team, which is highly qualified in testing and analyzing clutch systems and their interfaces with the vehicle. Aiming to support its partners in development and solutions of technical obstacles, that may hinder the comfort and durability of the vehicles, LuK performs and develops testing technologies for its products and the systems they are fit in. Thus, the tests are made on combustion engines, transmission noises and stresses, as well as on comfort and durability of the clutch pedal actuation systems Clutch Release Systems Knowledge is the key to success in clutch release systems. Vehicle drivers may evaluate the clutch and the release system comfort feeling the smooth coupling and decoupling behavior, the load-travel ratio and the absence of vibrations and noises during pedal actuation. When actuating the clutch pedal, the driver notes the release system response. To satisfy the requirements on the clutch pedal, the system components must be adjusted as for the tribology parameters, rigidity and mechanical relations LuK keeps high technological competence level in clutch release systems. 7. The Future of Cylinders LuK supplies master cylinders for the clutch release system with complete plastic project technology. In different dimensions, connection and fixing systems, the cylinders use piston, seal and lubricant material combinations, which keep the actuation process smooth and silent. In the same manner, the development of slave cylinders applies plastic materials integrating functions, assuring low weight and innovating in the use of such materials. 8. Piping-Easy Installation with Innovation On request, LuK coordinates the development of pipe installation and the supply of components. Besides, with the use of rubber / steel and plastic pipes, LuK, in association with technical partners, has developed a new polymer technology that allows flexibility in the installation, making easy the quick fixing and allowing similar routes as the cable route, with low volumetric expansion, reducing hydraulic losses at reduced application costs. 9. Expertise in Clutch Pedal System Projects Always concerned to offer the best technical solutions to meet the current demands on comfort, and approaching the pedal actuation load as well as noises and vibrations during actuation, LuK has created and has been continuously enlarging its professional team with experts specialized in pedals and load compensation springs. Moreover, LuK shows its competence in clutch release system and components, minimizing noises and vibrations, using technologies grounded on innovative solutions by means of plastics and polymers.

6 D e v e l o p m e n t Global Presence, Local Solutions LuK has always been present and close to its customers by locally developing, testing and manufacturing its products in order to meet the markets needs and overcome its partners expectations. The operations in Sorocaba, Brazil, count on a comprehensive structure to attend new projects requirements, from its conception to the serial production. LuK s concept is based on a customeroriented work, systematically participating in the definition and development s of the systems to uphold its products. The multidisciplinary teamwork, which involves professional people from Sorocaba and the branch offices from other countries and our headquarters in Germany, provided a regular diffusion of knowledge and allows the reduction of the response time to technical challenges. LuK stands for its special attention to its partners and strives for local solutions with global knowledge and technology. transmissions improve the transmission system's efficiency and combines the reduction in fuel consumption automatic transmission. These transmissions offer an excellent base to the progressive hybridizing of a transmission on a modular Prototyping Testing Expertise Project Tuning Product Development Process (PEP) Project Management PEP Process quotation Develop product Develop production process Prepare production Volume production Definition Prototype Optimization Production prelaunch Ramp-up Inquiry Quotation Define Modification functions & freeze processes Internal SOP Stable production

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