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Dynamic Ideas for Safe, Flexible andSustainable Production

VehiclesProducts · Services · Solutions

2272-00_EAT_OEM-Bro_Automotive_R2 2 02.09.2011 14:31:31 Uhr

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Welcome to Eaton – A Leading Energy Management Company of Our Time

Powering Business Worldwide –Discover the Global Energy From Eaton

Everything started with the production of truck axles – since 1911 we have beensupporting our customers with new innovations and products in safe, efficient and environmentally-friendly use of electrical, hydraulic and mechanical energy. Today we do this in our four business fields: Automotive, Electrical, Hydraulics and Aerospace. Get to know us!

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Photo: © BMW AG/Photographer: Stefan Hanke


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Wherever Eaton is present there is drive in the business

Eaton monitors, controls, protects and distributes the energy for thousands of products – daily around the globe. With the commitment and ideas of more than 70,000 employees, 20,000 of them in Europe, we keep our customers business on the move – effi-ciently and with the focus on the customer.

New technologies for a green future

Eaton is accelerating the development of new, sustain-able technologies – from hybrid drives and emission control systems to innovative engine components, which further reduce the fuel consumption and the gas emissions from commercial and passenger vehicles. Today, many Eaton products comply with the most stringent standards of sustainability and efficiency – we label these products with our Green Leaf symbol. Find out more: www.eaton.com/greensolutions

A global operation –just like our customers

The automotive industry in particular benefits from one of our core strengths – the global presence of Eaton. We see ourselves as an international company and embrace this fact. Eaton offers you comprehensive customer orientation on the market, because we meet the challenges of the global market with forward-looking and decentralized manufacturing.

High quality standards – the key to success

We pay particular attention to how our quality originates. Our corporate culture is based on impeccable ethical values – international awards and the top rankings under the “World‘s Most Ethical Companies” is a testament to this fact. Find out more: www.ethisphere.com

Worldwide resources – available on demand

Rely on the presence of a globally based organization – combined with proximity to the customer and on-location support. Fall back of the global resources for development, production, service and logistics, which are available, should they be needed. And be assured that we are present in your regions on-location, wherever and whenever you need us.

This is what characterizes Powering Business World-wide – we devote all our energy in driving forward your business.

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Automotive and truck

Innovative automatic trans-missions facilitate safe and economic handling of large trucks. Our revolutionary hybrid drives represent a new era for commercial vehicles.

Electrical sector

Energy management, energy distribution and power quality provide the prerequisites for the safe and efficient utilization of electrical energy in buildings and industrial installations.

Hydraulics

Eaton is one of the pioneering innovators in the development of efficient hybrid hydraulic systems for buses, commer-cial vehicles and construction machinery.

Aerospace

Elaborately constructed and therefore extremely light, the 5000 psi hydraulic system for the Airbus A380 saves weight, reduces fuel consumption and emissions.

We monitor, control, protect and distribute the energy for the innovative products and technologies of our age.


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Powering Electrical Systems Worldwide – Our Philosophy

Safety, Flexibility and Sustainability – for a Sector on the Move

Our goal is energy management that is always efficient – in the products that cover the needs of our fast-moving world. Whether it's cars, commercial vehicles, machines, buildings or industrial systems – all components from Eaton include safety and reliability as “standard equipment” – as these properties are indispensable. For this reason, Eaton is an exceedingly popular partner in the automotive segment.


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A safe electricalinfrastructure

Eaton offers a comprehensive range of solutions from medium-voltage right down to the electrical outlet for operation of a high-performance, flexible energy infrastructure for your overall system.

Flexible, fail-safe production lines

The fail-safe energy supply is a critical business factor which impacts directly the efficiency of the production line. Eaton makes the electrical energy required by your employees, machines and processes flex-ibly available at every point in your manufacturing operation.

Innovative and efficient vehicle components

Eaton is one of the driving forces in the automotive sector and its ancillary industries for almost a century. Sophisticated products ensure more driving safety, lower fuel consumption and higher efficiency, perform-ance and control – in all vehicle categories.

Trendsetting, sustainable eMobility

Clean mobility using electrical or hybrid drives, supplied by highly-efficient solar installa-tions – Eaton already has the right components in its range for this vision, both for use in vehicles as well as for implementation of the infrastructure.

The benchmark for energy efficiency – rediscover your infrastructure

In the automotive sector in particular, a safe, flexible and efficient energy supply is a decisive productivity benefit. Regardless of whether it is for production lines, development centres, IT or administration buildings – our leading energy management systems help you to reduce the energy con-sumption across your company and to further reduce a critical cost factor.

And not least you also reduce the emissions of greenhouse gasses – making your business “greener” and sustainable.

Strategically consider your electrical infrastructure and the automation of your installations – as a holistic system

The driving force for your development, produc-tion and ultimately your business is electrical energy and reliable automation of your machines and systems. We form an integral network of automation components such as motor starters and frequency inverters, sensors and control circuit devices as well as switchgear systems and UPS systems – as dynamic and adaptable to new challenges – like your business.

Eaton energy management – assume control of your infrastructure

Rediscover electrical energy for that what it really is – an indispensable business factor. The particular feature that you will only find from us: we have the strategic tools and services that you can use to observe and manage the lifeline of your production as an integral resource. We integrate tailor-made energy management into your workflow from the supply, to monitoring and protection, right through to maintenance. In this way, an incomparable integration density of solutions results, which optimize your energyconsumption, reduce your demand and increasethe sustainability and efficiency of your installa-tions day for day and hour for hour.

Our solutions in these four areas contribute in precisely delivering the demands of your markets.


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Tailor-Made Support – for your Entire Energy Management

Commitment and Competence – our Services for your Production

At Eaton, you will find a comprehensive support portfolio – for your entire production process. Our services are perfectly tailored to your electrical infrastructure, your automation, your machinery, your hydraulic systems – in other words, your requirements. We understand your sector, because we want you to manufacture as efficiently as possible.

We are at home in your sector

What we bring to the table is an in-depth knowledge of the sector and solution know-how, many years of experience in the automotive segment and the most modern processes and technology that keep up to pace with your innovation cycles.

We are there for you

Our engineers and service em-ployees understand their craft and your segment. They ensure that the service strategy, which optimally meets your demands, is implemented.

Solution-oriented consulting

Our engineering ingenuity and consulting competence is focused on your business requirements. The goal: workable strategies for your installations. We transform concepts to solutions – efficiently and directly.

Project support

Our specialists assist you tocomplete and optimize yourprojects – from the moderni-zation of existing installations to the establishment of new production lines.

Reliable service

At Eaton, we do not talk a lotabout reaction times, delivery periods and spare-part avail-ability. We guarantee them. You can rely on getting exactly the support that always secures the optimum performance of your system.


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Energy management for transparency, optimization and security

In many companies, not all critical infrastructural elements and installations are subject to inte-grated monitoring. And those that are monitored do not communicate with one another. What is missing in many installations therefore, is transparency and a perception of the overall picture. Eaton offers exactly this missing monitoring backbone with Power Xpert. You can for the first time profitably utilize your energy supply as a strategic asset.

Logistics – just in time

Our comprehensive service concept is supported by adequate logistics, which can deliver on the promises of reliability and efficiency – any time around the globe. Eaton delivers more than just the right product at the right time to the required location. Use our special logistics and added-value solutions ranging from individual packaging to customized labelling – to ensure that you also achieve your objectives just-in-time.

Every product is only as good as the service that covers it

This simple insight clarifies the significance that we attach to our service quality. Discover our possibilities – rely on the service and logistics backbone of a company with more than 70,000 employees. This concentration of competence ensures a unique quality – at the same time our worldwide presence is responsible in guaranteeing quick and direct access to our portfolio at any time – wherever you drive your business forward.

Our range of services

• Engineering and consulting

• Energy management studies

• Project management

• Modernization

• Energy quality and energy reliability studies

• After sales and field services


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Medium-Voltage Energy Distribution – Reliable, Safe, Efficient

Sustainable and Reliable Provision of Energy

Eaton offers a complete range of switching systems and components. Efficient, flexible products are available for a host of applications. A series of innovative systems are insulated by air and epoxy resins – and frequently equipped with circuit-breakers based on proprietary vacuum interrupters. The highest demands for safety, maintenance-friendliness and sustainability are thus assured.

Trendsetting sustainability – forgoing use of SF6

Every individual component, every configuration, every installation component is measured against our claim to make the best pos-sible and most efficient use of resources. Low levels of energy consumption and emission reductions are the driving factors for our innovations. The best example is our medium-voltage switchgear systems, which are not just more compact, but are also SF6 free.Avoidance of Sulphur hexafluoride (SF6) contributes significantlyin protecting the climate. However, the manufacture of this damaging greenhouse gas continues to increase. We take our responsibilities seriously and give our customers the opportunity to contribute to the worldwide reduction of SF6

emissions with SF6 free medium-voltage switchgear systems. A unique epoxy resin is used for insulation purposes. The inno-vative vacuum technology from Eaton provides reliable safety when switching.

Less space requirement, less maintenance - more efficiency

Energy distribution and switchgear systems do not just need to be efficient, but also safe and always switch reliably when it matters. We have further increased the reliability and maintenance friendliness and have once again reduced the space requirement and the number of components. Especially small vacuum tubes, fully enclosed housings, which exclude dust, moisture and other environmental factors – some-times less is more. On the new Xiria series we have even comple-tely eliminated lubricants – and they are thus maintenance-free.

Safe in operation – a matter of principle

Maximum operating safety is the top priority at every point in the electrical installation. Switchgear systems from Eaton provide more safety in every system – even during installation. The isolation state is clearly visible through a window at any time – and is clear and unambiguous to the operator.

Energy utility companiesMains

6.6 or 11 kV

up to 24 kV

up to 24 kV up to 24 kV

6.6 or 11 kV


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Power Xpert® UX 3.6–17.5 kV Medium Voltage switchgear with withdrawable technology

The tried and tested Eaton UX switchgear systems are ideally suited for use as motor control centres in the automotive industry and as power distribution stations. The robust construction with three millimetre steel plating and usage of Eaton vacuum interrupters makes the UX series extremely safe and reliable. This is one of the reasons why it is the system of choice in many applications in the automotive industry. Their modular configurable panels comply with the current IEC standard 62271-200.

Power Xpert® FMX medium-voltage switchgear from Eaton – compact, innovative and user-friendly

With its fixed circuit-breaker installation, the FMX busbar system sets the standard in connection comfort, compact design, oper-ating safety as well as user-friendliness. It is designed for appli-cations up to 24 kV – all compartments are in a position to conduct a short-circuit current of 25 kA for up to three seconds. Variants up to 2000 A and compact compartments from 500 mm in width let no wishes unfulfilled during configuration – leaving nothing in the way of efficient service in distribution networks and with the connection of industrial and utility companies.

Xiria 3.6–24 kV ring main units for energy distribution –the new generation in investment protection

Continual innovation guarantees optimum performance – this is also the case with the new Xiria series. The modern switchgear system combines the highest levels of reliability and operating safety for all applications up to 24 kV. At the same time, it is significantly more compact than comparable systems. Both the primary part of the unit and the mechanisms are housed in a fully enclosed housing, which protects the system against environmental influences and is almost maintenance-free. This level of flexibility allows you to quickly respond to all energy distribution requirements.

Power Xpert® Monitoring Solutions – transparent monitoring and analysis for all your energy distribution requirements

Eaton integrates all elements of your energy infrastructure into an integrated system linked by an Ethernet network. All information concerning the energy flow, the requirement and consumption come together in the Power Xpert® system. You continuously have an eye on all the energy-relevant results of your system and know how they are interrelated – allowing you to come to the right conclusions. It reduces the energy consumption, because the overall efficiency potential is exploited. Furthermore, the quality of the energy supply is improved – bottlenecks and potential outages can be detected in advance and quickly eliminated.


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Low-Voltage Energy Distribution – Distributed and Highly-Integrated

Profitable Energyin its Most Efficient Form

Solutions from Eaton are the first choice over the entire electrical network on the way from the power station to the consumers. Particularly in the low-voltage field, we offer the automotive industry a complete and absolutely convincing range of products. Our promise: Demand-driven, precise energy supply across your entire production – both continuous and fail-safe.

A new era of integration provides unimagined efficiency

Directly at the heart of your business, in production, the highest level of flexibility is required when demand-based energy distribution is involved. Our highly-integrated distribution and switchgear systems make the configuration of truly individual energy distribution architectures possible in the first place. It introduces medium-voltage directly into your production – precisely, where the conversion to low-voltage occurs.

This principle considerably reduces the space requirement. Furthermore, the planning of systems is simplified, because the energy infrastructure is orientated to the demands of the production lines and not vice versa.

Maximum flexibility and performance – in a minimum of space

As medium-voltage can be transmitted with lower losses thanlow-voltage, this will become evident in your energy costs. With the new, combined M2L integrated power distribution systems, conversion from medium-voltage to low-voltage is implemented decentrally – with precision and low losses. You only require one system, and it is positioned precisely where you require the corresponding voltages. The integration of both voltage worlds in a single installation eliminates the need for unnecessary low-voltage cables and the significant associated losses. Installation and maintenance are simplified accordingly.

Low space requirement – simplifies installation

Simultaneous integration and decentralization of your energy distribution leads to considerable cost savings even during instal-lation. Instead of a whole bundle of low-voltage cables, just a single medium-voltage cable leads to the distribution board. The connection to the transformer is implemented ex-works and tested – the installation is installed in a very short time.

Medium-voltage cable

Low-voltage Low-voltage cablecable

M2L distribution board

Technicalroom Transformerroom

Low-voltagedistribution board

LoadConventional situation

New situation with M2L distribution board

Medium-voltage cable

replaces low-voltage cable Load

Medium-Medium-voltage cablevoltage cable

Low-voltage Low-voltage cablecable


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Modular low-voltage distribution

Through their reliability, application safety, flexibility and efficiency, the standardized Eaton low-voltage systems are the modular basis for the configuration of high-performance switchgear systems. Our low-voltage switchgear systems are compliant to the highest demands such as degree of protection IP54 and the internal par-titioning to form 4a or 4b. They can be found in use worldwide – their variable application orientation and many options for more security and faster config-uration directly on location make them sought after systems.

ARCON arc-fault protection system – the robust airbag for switchgear systems

The extremely reliable arc-fault protection system ARCON from Eaton is used very successfully in low-voltage switchgear systems worldwide. The arc fault is not just detected, it is also “reliably” quenched – and that fast enough to ensure that there is no damage. The quenching unit generates a short-circuit – causing the voltage to drop-out – and quenches the arc within 2ms. This tried-and-tested technology introduces the maximum level of personnel and system protection to your production and also increases the availability of the protected installations and systems.

Circuit-breakers – safe and demand-oriented protection at overload and short-circuit

Compact circuit-breakers up to 1600 A in four sizes and open circuit-breakers up to 6300 A in five sizes provide individual sys-tem, line and even motor protection – with the highest level of flexibility. The Eaton range facilitates economic engineering design – and for example, the unit widths increases with the rated current. As a result, the most compact and cost-effective size can be selected. Furthermore, the risks of a costly installation standstill are reduced to a minimum.

XP series busbar trunking system – the reliable and flexible backbone of power distribution up to 6,300 A

With their concept that is just as economic as it is safe and their innovative sandwich design, the XP busbar trunking systems from Eaton offer an unbeatable range of applications from 500 to 6,300 A – they master practically every installation challenge. All components are extensively tested and comply with the IEC standard 60439-2. Trunking systems for low-voltage and medium voltage, numerous tap-off units and a comprehensive range of accessories offer the practical solution for establishment of an absolutely reliable energy distribution system.


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Maximum security for your data center

The integrity of IT applications are decisive for business-critical areas. This is why an uninterrupted energy supply is a prerequisite for failure-free business processes. You can rely on your infor-mation systems with Eaton as a partner, because no data and processes are endangered even in the event of a power outage.

Reliable protection for your building infrastructure

Important systems and components must remain available even during a power failure in industrial systems and buildings. UPS solutions from Eaton ensure this. Emergency lighting, safety systems, fire alarm systems and building management continue to work reliably – even during serious faults on the main energy supply.

Fail-safe reliability for your entire process automation

The uninterrupted availability of production lines, process control and automation systems is an indispensable prerequisite for the productivity of your locations. This is why we protect your process against energy failures – and accordingly against costly standstills. Our robust UPS systems comply with stringent demands of manu-facturing environments and operate smoothly under extreme ambient conditions.

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Uninterruptable Power Supply for Critical Applications

Reliable Energy for Productionthat Permits no Standstill

Eaton offers a wide ranging and diverse product range to protect your business processes, applications and systems. More than 45 years of experience in the design and manufacture of innovative UPS systems is invested in our solutions. They support your company around the globe in maximizing your profit – by ensuring fail-safe energy supply for all systems and installations.

Eatons portfolio for data centers ranges from switching, distrib-ution and protection of electrical energy in the low-voltage and medium-voltage range to the protection of critical IT systems and installations from energy related problems of every kind, right up to the safe energy supply of the individual server.


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Single-phase UPS solutions

A highly dynamic sector: Technologies, processes and workflows are exposed to the continuous change in the automotive sector. It is therefore not surprising that the demands on a safe, reliable and at the same time highly flexible energy supply continue to increase.

Eaton has the answers – beginning with a complete range of single phase UPS systems. Both the Powerware as well as the Pulsar series protect your IT systems and your industrial applications reliably and efficiently against fluctuations in the main power supply.

Three-phase UPS solutions

The proven Powerware series with its wide range of three-phase systems forms a highly reliable, central solution for the protection of the energy supply to your systems, buildings and processes. Our products are in use worldwide in many sectors and industries – and they stand out due to their high-performance, reliability and efficient , cost-effective use of energy. Briefly, they are the first choice for critical applications.

ePDUs – maximum security, highly-integrated

IT specialists require future-proof, transparent solutions in order to safely access the required energy and to clearly and trans-parently monitor the availability. These demands are fulfilled by the intelli-gent rack-based energy distribution solutions of the highly innovative ePDU product series. It offers great flexibility and cost-efficiency by using clever tools, which, for example, keep the data center under control at all times with utmost transparency and absolute control.

Power management – transparent energy monitoring

IT system administrators need to know when their energy supply is impaired. Building managers must be informed when the tem-peratures in the UPS or battery room rise, and the service manager needs to be alerted should the components in the system fail.

Eaton Power Management solutions implement the connection of networks, IT, building engineering, automation and building management – via innovative software and connectivity products. They provide precisely the information that the relevant specialists require - via e-mail, mobile devices and web interfaces.


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Solutions for More Security – in all Areas of your Production

Safe Control of Processes – Controlling the Unexpected

Safety to the latest standards

With the Safety Technology product range Eaton offers future-oriented components for reduction of risks – compliant to the highest demands of international standards. The safety-related applications and functions in a machine control incorporate the entire functional chain – commencing with safe and fast detection of all relevant information via the input level. Reliable processing of signals is undertaken on the logic level – and the demand-based reliable reaction of the display to shut-down in the output level.

Safety and standard technology efficiently combined

Machine safety at maximum productivity is a fundamental requirement in production automation. The configurable control relay easySafety is the optimum solution for safety-related tasks combined with control engineering. Equipped with a host of conventional safety relays, easySafety also integrates standard functions into just one device. This is how the simplicity of safety relays is combined with the flexibility and performance of programmable systems – simply easy.

Protection of personnel and systems in welding shops

Personnel protection – protection against electrical shock – is implemented by the fast and automatic switch off of dangerous touch voltages. Together with the directly mountable RCCB modules, the circuit-breaker NZM fulfils all demands made of protection systems for protection for persons and installations. The RCCB circuit-breaker reacts immediately when the set rated fault current is exceeded. The electronic circuit-breaker NZM also correctly evaluates the harmonic frequencies that occur in welding systems – and thus helps to reliably increase the operational continuity.

Systems for accident prevention such as ESP, ABS, safety passenger compartments,sophisticated airbag systems, etc. have accommodated the increasing demands for safe vehicles and passenger safety requirement. The same demands on safety also apply for the manufacturing process in the automotive industry. The machine manufacturers are legally obliged to protect people and machines by specific checks and mastering of hazardous movements.


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Reliable protection of hazardous areas and fast detection in an emergency

People, machines and capital goods are protected using the EMERGENCY-STOP buttons from the RMQ range or the easy to actuate foot and palm switches. Rotary switches, switch-disconnectors and motor-protective circuit-breakers are available for EMERGENCY-STOP functions as power disconnecting devices. Safe monitoring of safety gates and protective covers optionally equipped with interlock devices are guaranteed by the tried and tested position switch LS-Titan – in conjunction with forcibly operated contacts.

Flexible, safe and fast acting – to varying machine requirements

Whether it's the electronic safety relay ESR5 or the new safety relay easySafety – safety-relevant signals are monitored reliably, processed quickly and the enable paths are switched with the assistance of safe outputs. All necessary safety functions such as EMERGENCY-STOP, safety guard monitoring, light grids, light curtains, muting functions, two hand control, safe timers, standstill and high speed monitoring can be fl exibly and easily implemented – with dynamic functionality for reliable machine safety.

Reliably switch off potential hazards

Safe switching is implemented with the robust, compact contac-tors – supported for reliable monitoring by mirror contacts or with the assistance of forcibly operated contacts. Particularly innovative is the safety-oriented shut-down with the new contactor monitoring relay CMD. The system eliminates the cost-intensive requirement for redundant contactor design in safety-oriented controls – as the main contacts of the contactor are continually monitored for welding.

Digital RCCB: State-of-the-art in the automotive industry

Whether for 3-pole or 4-pole standards – the new digital residualcurrent devices from Eaton are powerful multifunctional “body-guards” that provide distributed safety in many areas of the systems. They are as intelligent as they are vigilant – they safely guard against fault currents. The digital bodyguards immediately indicate any irregularities – with the LEDs integrated on the switch, etc. If danger is really present, it switches off with utmost precision – faster and more precisely than conventional analog circuit-breakers.

Photo: © BMW AG/Photographer: Stefan Hanke


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Solutions for More Flexibility and Economy – in all Areas of your Production

Lean Connectivity and Lean Automation for Flexible and Economic Solutions

The balancing act between increasing demands on the functionality and costing pressures is a constant challenge particularly in the automotive industry. Lean is our philosophy in the optimization of planning, production and commissioning. Lean in automation means simple and linear concepts utilizing fewer components. Lean connectivity means plug-in SmartWire-DT connections and direct communication.

SmartWire-DT – innovative communication with system

For the control of industrial processes with increasing complexity, you must strive to achieve a balance between the maximum level of functionality and cost optimization. SmartWire-DT meets this challenge – it is a modular communica-tion system design concept for industrial switchgear in the control panel and in the peripherals. From control through to protection and switching, and extending to drive, operation and monitoring, a pioneering technology is universally integrated – from which you can benefi t today.

Lean connectivity – connecting instead of wiring

Conventional wiring of control circuit devices involves a lot of effort and expense. It requires a lot of time and has the potential for many faults. SmartWire-DT on the other hand is simply ingen-ious – the fl at green cable connects control circuit device using connectors with just a click. Precisely this saves time, avoids wiring errors and enables fast troubleshooting. SmartWire-DT saves costs – from the design to the construction right up to test and commissioning.

Cleverly integrated – starters, contactors, control circuit devices

Control circuit devices form a unit in conjunction with SmartWire-DT components. Furthermore, the tried-and-tested Eaton industrial switchgear can be simply integrated – with just a “click” you have communication capability. Thus a PLC is possible without complex control wiring.

The combination of the Eaton core competence HMI-PLC and SmartWire-DT leads to economically and technically optimized lean connectivity and lean automation solutions.


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Enhanced machine availability with PKZ and PKE

Motor-protective circuit-breakers PKZ are the embodiment of reliable motor protection. The electronic motor-protective circuit-breaker PKE continues this tradition with expanded functions. The large range of motor-protective circuit-breakers used up to now can be reduced considerably by the exceptional wide-range overload protection of the PKE series. Just five device types cover the entire range from 0.3 to 65A. The energy consumption and heat development have been reduced by the optimized constructive features. The PKE series fits seamlessly into the SmartWire-DT network. Numerous status and diagnostics mes-sages of the connected motors provide data transparency, and this helps to significantly increase the manufacturing availability.

Simple and high-performance – the SmartWire-DT technology

SmartWire-DT is innovative, for universal use and highly inte-grative. All communication and switching functions are integrated into one electronic component – miniature switchgear components such as pushbuttons, switches or display elements are also perfect for configuration. The system is expandable as required – with up to 99 nodes and a SmartWire network than can extend by up to 600 metres. Thus applications outside the control panel are also possible. SmartWire-DT can be integrated into every environment with digital or analog data transfer and PLC integration via standard fieldbus systems.

Flexible visualization with the most modern touch technology

The demands made of modern visualization in machines and system engineering are manifold – the touch panels of the XV100 and XV400 series are just as flexible. They facilitate consistent engineering with variants from 3.5“ to 15“. Two different touch technologies (infra-red or resistive), a wide range of communication interfaces and application-oriented housing concepts guarantee first class interoperability. All visualization devices can be operated as pure HMI or as HMI-PLC devices. The common, tried-and-tested and flexible hardware platform guarantees the greatest possible reliability and long-time availability.

Optimized valve solutions for creative motion control

The new generation of hydraulic valves from Eaton is based on the proven KB series. With four performance stages and a modular design, they facilitate cost-effective solutions for differential control of synchronized movements. Robust design and comprehensive diagnostics functions, an open architecture and high-performance precision are combined – proportional valves are the basis for individual automation solutions that considerably enhance the machine performance and set new benchmarks for differentiated productivity. With Eaton CONTROL F(x)™ an open standardized programming environment compliant to IEC-61131-3 is also available.

Photo: © NedCar B.V.


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More Sustainability in all Areas of your Production Workflow

Safe Energy Flow Meteringand Sustainable Optimization

Responsible use of our environment and its resources is now a matter of course in all sectors of industry. Sustainability plays a significant role in a segment of industry so heavily dependent on energy like the automotive industry. Eaton took on this challenge at an early stage and drove forward the optimization of energy use in all product areas.

Safe and economic metering of energy use

Responsible use of energy is now more necessary than ever before for economic and ecological considerations. However, when there is a requirement to take concrete measures to enhance the energy efficiency on machines and installations, users are faced – particularly on existing systems – with the challenge to first of all clearly identify the energy intensive pro-cesses and then to make expedient energy efficiency modi-fications. Eaton offers a comprehensive range of energy measurement and communication modules to provide transparency regarding the energy consumption of a production system. The XMC metering modules can be used universally in conjunction with compact circuit-breakers NZM and application-oriented in energy supplies or energy feeders.

Measurement and communication

The XMC modules provide all the relevant measured data for the calculation of the energy consumption: Phase and N conductor currents, effective voltages, active, reactive and apparent power. The modules are designed for a voltage range of 35 to 690 V, a current range of 1.5 to 630 A and a frequency range of 50 to 60 Hz. The accuracy class is 0.5 and is thus extremely precise for company-internal cost accounting. All data can be accessed via Modbus RTU. For example, the energy consumption of a manufacturing machine is not just measured, the costs can be assigned to the manufactured product.

New compact solution in one enclosure

The integration of current transformer, voltage tap-off, measure-ment electronics, fieldbus interface and display interface in a single enclosure is a just as innovative as it is efficient. As many individual devices – three current transformers and a measuring device – are integrated into a single housing, wiring and mounting costs that are not inconsiderable are eliminated.

XMC S


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Energy-effi cient command and signalling with LEDs

The entire RMQ and XMC switch range is designed for harsh industrial environments. Ergonomic modern design guarantees an optimum functionality – and not least error-free operation. Prominent features are the high degree of protection IP66 and LED technology with a particularly long service life and high resistance to vibration. Eaton offers the right switch and button even for special demands – an example of which would be thefoot and palm switches FAK.

Frequency inverters M-Max – for universal use, sustainable energy-saving

High levels of functionality must not be complicated to operate: User-friendly in design and with comprehensive diagnostic func-tions, the frequency inverters of the M-Max series facilitate easyadaptation to the drive – particularly to the demands of the auto-motive industry. The series offers the highest level of fl exibility for motor outputs from 0.25 kW to 7.5 kW. The small and compact design in book format enables a space-saving design. With an inte grated radio interference fi lter (EMC) and fl exible interface, M-Max also solves all the important requirements in the vehicle construction. Worldwide use is assured by the approvals to global standards.

Contactors DIL with DC actuation save energy and reduce operating costs

All DC contactors with DC actuation of 17 A to 65 A have a holding power of only 0.5 Watts. Even at 170 A, a holding power of just 2.1 Watts is required. This not only reduces the direct energy consumption, but also the heat dissipation. The positive consequence is lower heat dissipation. A higher packing density can be achieved in the control panel. Dissipation of the heat using expensive and energy consuming fans is unnecessary. In this way, energy costs are reduced, and attractively-priced control concepts are made possible.

Circuit-breaker NZM – comprehensive protection at short-circuit and overload

The circuit-breakers NZM cover a rated current range of 15 A to1600 A with just four sizes. The comprehensive range of acces-sories is also excellently matched to the varying requirements of the automotive industry. Application in production, e.g. in solutions for welding robots as well as in logistics and for effi cient energy distribution are quick and simple to implement. With a switching capacity of up to 150 kA, the optimally matched switches meet the highest performance demands.


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Solutions and Components for Vehicle Equipment

Tailor-Made Functionalityfor Every Vehicle Class

For more than a century, Eaton has been supplying the commercial vehicle sector with versatile components, which are designed to enhance the performance and service life, and thus increase the profitability of the vehicle. In the models from all the leading manufacturers, Eaton provides the drive-trains, gearboxes and safety components as well as displays and switches. They fulfil the highest demands in terms of ergonomics, fail-safe protection and not forgetting sustainable fuel consumption reductions – day for day, component for component.

Highest performance and customized design

Very durable and reliable products are essential on the commercial vehicle and bus market. Eaton offers just this – multiplexed sys-tems, sensors and switches, designed for the most extreme and difficult mission applications. Furthermore, individuality is demanded in all automotive manufacturing segments. It is a matter of course that all components get the look and feel of their marque. Irrespective of whether it is a delivery vehicle or a heavy-duty truck, the operating and display elements in the cockpit provide a cross-platform design. Innovative production methods enable this customized adaptation.

Green, sustainable technology for commercial vehicles

More and more vehicle components play their part in the reduc-tion of fuel consumption and environmental pollution and in further increasing the mission efficiency. Eaton offers many solutions to this end. With the intelligent HLA technology, a braking system is available, which at the same time is a drive system – and that hydraulically supplements the torque of the engine with the stored braking energy to assist during initial acceleration. Productivity increases from 8% to 12% as well as up to 25% less fuel con-sumption are realistic. The service life of the braking system is extended many fold, which reduces costs and protects the environment. A further highlight are the variable pumps that can provide the power on demand and that also considerably reduce the fuel consumption. The environmental properties of commercial vehicles that are in demand include low noise emissions and savings in weight. Here too, Eaton has answers in many areas – from extremely quiet pumps to noise-suppressed hose lines.

1 Cost reducing FX solutions – e.g. elevation control, remote monitoring, diagnostics and productivity display

2 Multiplex switching – enhances the service life, reduces weight, simple installation and maintenance

3 POD pumps – highest consumption and cost efficiency4 Sensor solutions – longest service life, universal use5 HLA braking system – lower fuel consumption, fewer

emissions, longer service life6 Fluid conveyance – highest load capacity, lower noise

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Innovative Eaton Technology on board – for more cost-effectiveness and higher productivity


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EngineDriveshaftDriveshafttDriveshaf

Low PressureReservoir

High PressureAccumulator

Trans Pump/Motor

Compact and highly integrated – multiplex switch solutions

With a wide range of confi gurations and designs, the multiplex switches from Eaton cover every demand in the commercial vehicle segment. The individual confi guration option simplifi es the design of dashboards and control elements. Complex and expensive cabling is largely superfl uous due to the high level of integration and the modular design. Furthermore, digital communication interfaces create the connection to the outside world. The integrated solutions include • Electronic multiplex switch module (eSM)• Electronic vehicle display (eVu)• New generation rockers (NGR)• Sealed vehicle rocker (SVR)

Sensors from Eaton – very rugged and versatile

A wide range of sensors enables mechanical, optical, capacitive and inductive object recognition. From the extremely robust mechanical sensors for the E50 series in metal enclosures to the programmable iProx sensors, Eaton offers a wide range for different mission profi les. iProx sensors can be easily adapted to the selected task with their ProxView programming under Windows and their integrated Teach function. Their corrosion-resistant stainless-steel enclosures and a temper-ature range down to -40 °C combined with the unique vibration-proofi ng explain why these sensors are used in different vehicles just as they are in automotive production.

Performance on demand – robust and versatile piston pumps

Eaton is driving the replacement of the conventional constant pumps by variable, highly-effi cient variable displacement pumps in commercial vehicles with the new power-on-demand technology (POD). The pump output is fl exibly adapted to the respective requirements.A high compression is also available at idle. The sum of the inno-vations leads to a signifi cant reduction in noise – and in day-to-day use to a remarkable saving in fuel consumption of between 10 % and 25 %. The POD pumps from Eaton also protect the environment – in case of a rupture in an oil line, a quick manual or automatic system shut-down drastically reduces the oil loss.

Brakes with regenerative energy – the HLA system

Innovative and sustainable – the innovative Eaton HLA system is a parallel hydraulic braking system that generates regenerative energy. The energy that results with every braking action is stored hydraulically and not dissipated as heat. An innovative pump-motor combination utilizes the kinetic energy of the vehicle during braking and pumps the hydraulic fl uid into a high-pressure accumulator. During initial acceleration, this fully automatically increases the torque of the combustion engine and thus signifi cantly reduces fuel consumption. The saving effect is particularly signifi cant on vehicles with a start-stop system.


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Solutions and Strategies for Comprehensive eMobility

For a Green Future: From Power Generationto the Charging Station

It does not matter whether it is public transport or individual traffi c – green mobility requires sustainable energy and an innovative electrical infrastructure. More than 20 years ago Eaton commenced with the development of hybrid drive systems – today we are the leading supplier of ready-to-use electrical and hydraulic hybrid systems for commercial vehicles and busses. Furthermore, Eaton also supplies modules and infrastructure solutions for vehicles with electrical drives (EV) and Plug in Hybrid Electrical drives (PHEV).

Proven in practice: Hybrid drives from Eaton

The term hybrid drive stands for drive concepts with two different energy sources. The technology, which is available today, is deci-sive for the reduction of fuel consumption and emissions on combustion engines and at the same time a signifi cant step in a green future, which relies on sustainable energy sources. Eaton is a leading technology provider in this fi eld.

Some of the companies that employ our technology include Daimler, Iveco/Fiat, DAF/Leyland, Freightliner, Ford and Solaris as well as DHL, FedEx, UPS and Coca-Cola. In close co-operation with these companies over a period of ten years, we have tested and documented the performance of more than 2400 commercial vehicles with Eaton hybrid systems. The vehicles with our drives have covered more than 50 million kilometres and in total have saved about 4.5 million litres of fuel and 12,000 tonnes of CO2.

The pillars of eMobility: Renewable energies, data and charging infrastructures

Whereas the integrated energy storage unit in hybrid electrical vehicles can only be charged using braking energy or the Diesel engine, vehicles with Plug-in-Hybrid electrical drives feature a charging device facilitating additional charging of the vehicle batteries at any time at quick recharging stations for electrical vehicles.

Eaton has innovative products and solutions for the implemen-tation of effi cient photovoltaic and wind power installations, that decentrally supply the EV charging stations with regenerative energy. From power inverters to switchgear installations and voltage protection systems right up to the feeder units for bi-directional connection to the public grid – our range is complete, available for delivery and offers all relevant components from a single source.

Eaton is thus the only supplier world-wide for this extremely dynamic market that not only delivers hybrid drives, but also the electrical infrastructure for their reliable, wide-scale operation.


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Innovative and sustainable – regenerative energy generation

With the global increase in power requirement, the increasingly effi cient utilization of solar energy is not just a trend, but rather an essential necessity. Eaton is a driving force here – our marketleadership is the result of many years of experience with inno-vative photovoltaic applications. Power inverters are key technology in this fi eld. Our PV power inverters convert the DC power in solar installations reliably intoAC voltage. The new Eaton generation has been specially devel-oped for European requirements. With their unique, integrated convection cooling they are highly reliable and maintenance free featuring protection degrees IP43 and IP65 for all environments.

Safe switching of DC voltage

DC applications such as photovoltaic installations or storage batteries require highly-developed switchgear systems. Eaton also offers a comprehensive product range here: Compact switch-disconnectors, protective and voltage enabling switches, string circuit-breakers – for every application up to 1,000 V and 1,600 A, with IP20 or IP65 protection. Maximum safety in the event of a fi re is provided by the Eaton fi reman’s switch SOL30-SAFETY, which disconnects the cable from the solar panels to the power inverters facilitating fi re fi ghting without an electrical hazard. It is simply installed in the immediate vicinity of the PV module in the DC current line between the panel and power inverter.

Reliable energy measurement – with SmartGrid

The distinguishing factor between today's power grids and the SmartGrid of the future is the bi-directional fl ow of current. Electricity will no longer just be transported from the energy generators to the consumers – every consumer can become a generator. More and more electrical energy will be fed into the public grids from regenerative energy sources such as solar power and wind power. Power feeding stations require intelligent, electronic measuring technology, which reliably meters, documents and controls the energy fl ow. In this smart metering application fi eld, Eaton works together strategically and successfully with technological leaders such as the Echelon Corporation.

Quick charging with EV charging stations from Eaton

Eaton is one of the pioneers in the development both of DC quick charging systems for electrical vehicles as well as for AC charging technology. Our DC quick charging systems achieve a capacity of 80 % in less than 30 minutes – and this enhances the suitability of electrical vehicles for daily use. In a large-scale fi eld test in California – the “Electrifi ed Highway” initiated by Mitsubishi Motors – our charging stations proved their value by reliably pro-viding the new i-MiEV from Mitsubishi with energy. Effi cient solutions for the implementation, monitoring and maintenance of charging stations and grids are no longer dreams of the future at Eaton; they are an integral part of our product range.


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E-Mail: [email protected]: www.eaton.eu/electrical/automotive

Published by: Eaton Corporation Electrical Sector – EMEA Eaton Industries Manufacturing GmbHRoute de la Longeraie 71110 Morges, Switzerland

© 2011 by Eaton Industries GmbHSubject to alterationBR08301001Z-ENPrinted in GermanyArticle No. 156674

4015081532643

Eaton’s Electrical Sector is a global leader in power distribution, power quality, control and automation, and monitoring products. When combined with Eaton’s full-scale engineering services, these products provide customer-driven PowerChain™ solutions to serve the power system needs of the data center, indus-trial, institutional, public sector, utility, commer-cial, residential, IT, mission critical, alternative energy and OEM markets worldwide.

PowerChain solutions help enterprises achieve sustainable and competitive advantages through proactive management of the power system as a strategic, integrated asset throughout its life cycle, resulting in enhanced safety, greater reliability and energy efficiency. For more information, visit www.eaton.com/electrical.


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