VS - Electrical Systems From Stop-Start to Hybridization

« Trust the Electrical Systems Specialist » With a strong leadership in Original Equipment and more than 30 years in remanufacturing, Valeo provides one of the best offer in starters and alternators: over 100,000 starters and alternators units per day worldwide on its production, and it is thus recognized as a key player on the global market, and leader in Europe. One out of three vehicles is fitted with a Valeo machine as original equipment. Valeo’s Aftermarket combined offer of “New for New” and remanufactured or “Standard Exchange“ products allows Valeo to answer each customer specific needs. The “Standard Exchange” range provide an economical solution whatever the vehicle to repair. With over 30 years of experience, strong knowledge in renovation techniques and in-house expertise in manufacturing electrical systems as original equipment, Valeo ensures high quality remanufacturing, in the total respect of O.E. standards throughout the whole process. Using the same process of inspection, cleaning and electric/ electronic testing, Valeo is able to renovate it’s competitor’s technologies.

Cores are at the heart of this process. Once collected, starters and alternators are sent to specific production units as they require different production treatments. All Valeo products are 100% asbestos free. In order to make the collection of old machines (starters, alternators and also compressors) more efficient, Valeo has developped the eCORPS system: a combination of a mobile terminal and software program to enable real time reliable recognition and data transmission of collected parts for a credit on surcharge in 48 hours.

The “New for New“ products range consists of numerous part numbers for professional vehicles (light utilities, trucks, buses, agricultural vehicles, tractors, fork-lifts...).It’s 100% O.E. quality to satisfy repairers and drivers who wants O.E. only. Valeo pursues its time-to-market initiative to propose the replacement part at the same time as the new vehicle model is released.

Table of Contents

1. Disclaimer

5 6 7 8

2. Valeo Techassist 3. Valeoscope library

4. Valeo, the Electrical Systems specialist

10 11

5. The quest to reduce CO 2 6. Homologation cycles

Regenerative braking

43

The early stage of regenerative braking in the main 12v battery To more energy recovery with i-StARS Gen3 18. Valeo in the race for affordable Mild-Hybrid .

45 46

7. Stop-Start function, a concrete answer to reduce CO 2 12 8. Micro-Hybrid Stop-Start system at a glance 13 9. Valeo StARS system 14 System overview . 15 The StARS machine 16 The StARS controller 16 StARS - in alternator mode 16 StARS - in starter mode 19 10. Belt drive designs 22 The wrap angle 22 Automatic tensioners 23 11. Belt Starter Generator drives 24 To new Front End Accessory Drive 24 Engine acyclisms 25 Engine downsizing and acyclisms level 26 Single stage BSG tensioner 26 Dual stage BSG reversible tensioner 27 Decoupling Alternator Tensioner 28 Mounting 28 Operational behavior 28 Benefits 29 High-capacity V-ribbed belts 29 12. A fast, smooth and flexible drive 30 For a quick engine start 30 For better NVH performances 30 For reflex start features 31 For stalling comfort 31 13. i-StARS, the challenge 33 System overview 33 The i-StARS machine 34 14. What’s more with i-StARS? 35 Boost /Torque assist 35 Regeneration capacity 35 Engine-Off coasting and reflex start 35 The reflex start offer 36 15. i-StARS scalability 37 16. “i-StARS +” to more power 38 17. i-StARS Gen3 - From Micro-Hybrid to Mild-Hybrid 39 Mild-Hybrid architectures 40 Benefit from vehicle kinetic energy 42 emissions and fuel consumption 11 What are Stop-Start benefits? 11 Stop-Start is at the heart of car makers’ strategy

47 48 49

19. Valeo e-Charger

20. The reinforced starter ReStART

Challenges faced by ReStART machines

49 50

The ReStART machine

Two ReStART families for more flexibility 51 21. Impacts on the electrical system 52 The cranking pulse 52 Secure the cranking capacity and stabilize the board net voltage 53 The load balance 53 Stabilize the board net voltage 53 22. A few reminders on battery characteristics 54 Nominal voltage: 54 Terminal voltage (V) 54 Open-Circuit Voltage (V) 54 Battery nominal capacity (Cn) : 54 Battery Cold Cranking Current (CCA) 55 State of Charge (SoC) 56 Internal Resistance 57 23. Cranking capability vs. Depth of Discharge 58 Evolution of Cranking Capability at Low Temperatures 59 24. Monitor battery activity 61 The battery sensor 61 Stop-Start status versus State Of Charge 63 25. To new battery types & classification 64 New technologies for new applications 64 What is stratification in batteries? 65 26. New standards for new batteries 66 Micro cycling 66 Dynamic charge acceptance 66 Endurance 66 Classification of types 66 27. Stop-Start management 67 Engine working conditions 68 Battery State Of Health (SoH) 68 State of Function (SoF) 68 28. Stop-Start systems diagnostics 69 Analyze before changing parts 69 Stop-Start disabling after servicing operations 70 Battery disconnection 70 Battery change 70

Foreword

Valeo Service We Care 4 You

Trust the Specialist

With a strong leadership in Original Equipment and more than 30 years of remanufacturing experience, Valeo provides to the Aftermarket with one of the best offers in starters and alternators, from latest innovations and O.E. quality spare parts to Stop-Start systems. Valeo comes to you with its expertise, a complete service offer to better answer to your needs and more than 3 200 references for Passenger Cars and Heavy Duty applications available in New-for-New and Standard Exchange. Valeo Service supplies Original Equipment spares and replacement parts to the Aftermarket. It offers all aftermarket channels worldwide a broad range of products and services to help boost the efficiency of repair services and to provide greater safety, comfort and driving pleasure. Trust the Aftermarket specialist with over 4,800 new products added each year, covering 14 product lines for passenger cars and 11 for industrial vehicles.

Providing workshops with the most precise, up-to- date, and relevant technical information is a key for efficiency and productivity everyday. Valeo dedicates for garagists a massive program designed to reach its customers at the core of their day-to-day tasks. Technical Promotion, Workshop tools, Technical Support and Technical Assistance are the 4 pillars of Tech’Care Program. The Valeoscope Handbook is part of the program and aims at providing the sharpest technical information for the market. As an aftermarket specialist Valeo Service cares for its customers in many dimensions and sets the basis of a long-term relationship. Valeo Service focuses on getting as close as possible to its partners, to better understand their day to day preoccupations, and delivers a service perfectly adapted to their specific needs. This is the perfect embodiment of the entity strategy: “We Care 4 You. Trust the Specialist”

2

1

Disclaimer

Whilst we endeavor to ensure that the information included in this training documentation is correct, we do not warrant its completeness or accuracy; nor do we commit to ensuring that the material on the documentation is kept up to date. To the maximum extent permitted by applicable law, we exclude all representations, warranties and conditions relating to this documentation and the use of this documentation (including, without limitation, any warranties implied by law in respect of satisfactory quality, fitness for purpose and/or the use of reasonable care and skill). Nothing in this disclaimer will: (a) limit or exclude our or your liability for death or personal injury resulting from negligence; (b) limit or exclude our or your liability for fraud or fraudulent misrepresentation; (c) limit any of our or your liabilities in any way that is not permitted under applicable law; or (d) exclude any of our or your liabilities that may not be excluded under applicable law.

The limitations and exclusions of liability set out in this Section and elsewhere in this disclaimer: (a) are subject to the preceding paragraph; and (b) govern all liabilities arising under the disclaimer or in relation to the subject matter of this disclaimer, including liabilities arising in contract, in tort (including negligence) and for breach of statutory duty. To the extent that this documentation and this training documentation are provided free of charge, we will not be liable for any loss or damage of whatsoever nature. The content of this Document is protected by intellectual property laws including copyright and trademark law. Its content, including texts, pictures, drawings, logos, trademarks is part of Valeo know how and is Valeo’s sole property. This Document and its content could not be used without Valeo’s written prior consent. Any non authorized copy, duplication, distribution or reproduction is strictly prohibited and any infringer could be prosecuted.

5

2

valeo-techassist.com

Valeo Techassist can support you all the way through the following service processes: ●● Product information: product data sheets with details not included in the catalogue. ●● Common failures: step-by-step failure diagnosis guides. ●● Updates about Valeo Service products: access to all Technical Service Bulletins. ●● Help through FAQs and the Valeo Service technical hotline ●● Valeo workshop tools: user manuals, service manuals and software updates on Valeo Service tools. ●● Online training modules (e-learning) about most modern product technologies. ●● Interactive feedback: - add your personal feedback to Valeo Service and contribute to future documents. - provide satisfaction feedback.

Valeo TechAssist is a web based application, specifically developed for repair workshops, automotive spare parts distributors and technical trainers. Valeo TechAssist is available online in 10 languages. Logon to the website at www.valeo-techassist.com. Valeo TechAssist is not only a technical database, but also a learning platform and a forum of information. It covers passenger cars and all Valeo product lines. The information in Valeo Techassist is structured in four comprehensive sections:

1. Product documentation 2. Technical assistance 3. Workshop tools 4. Technical training

6

Valeoscope library

3 Take benefit from the Valeoscope Hand Books library to discover Valeo technologies. ●● Systems environment and constraints ●● Systems working principles ●● Systems evolutions ●● Servicing and fitting advices Technical handbooks Valeoscope library Air conditioning valeoscope The A/C system Thermal comfort loop a b c Technicalhandbook 998321 -VS -AirConditioningSystems -TheACSystem -Technicalhandbook valeoscope -EN.indd 1 19/01/2016 15:19 valeoscope Lighting Systems From light to advanced vision technologies a b c Technicalhandbook 130167 -VS - LightingSystems -Lighting -Technical handbook valeoscope -EN.indd 1 19/01/2016 14:58 Technical handbooks Valeoscope library Air conditioning valeoscope The A/C system Thermal comfort loop a b c Technicalhandbook 998321 -VS -AirConditioningSystems -TheACSystem -Technicalhandbook valeoscope -EN.indd 1 19/01/2016 15:19 Air Conditioning Ref: 998321 valeoscope Lighting Systems From light to advanced vision technologies a b c Technicalhandbook 130167 -VS - LightingSystems -Lighting -Technical handbook valeoscope -EN.indd 1 19/01/2016 14:58 Lighting Systems Ref: 998542 Technical handbooks Air conditioning valeoscope The A/C system Thermal comfort loop a b c Technicalhandbook 998321 -VS -AirConditioningSystems -TheACSystem -Technical handbook valeoscope -EN.indd 1 19/01/2016 15:19 Air Co iti ing Ref: 998321

valeoscope library Valeoscope library Lighting Systems From light to dvanc d vision technologies

Technical handbooks

valeoscope

a b c

NEW

Technicalhandbook

130167 -VS -LightingSystems -Lighting -Technical handbook valeoscope -EN.indd 1

19/01/2016 14:58

Air conditioning

Lighting Systems From light to advanced vision technologies

Lighting Systems Ref: 998542

The A/C system Thermal comfort loop

Air Conditioning Ref: 998321

Lighting Systems Ref: 998542 Product focus

Product focus

valeoscope

valeoscope

a b c

a b c

Technicalhandbook

Technicalhandbook

998321 -VS -AirConditioningSystems -TheACSystem -Technicalhandbook valeoscope -EN.indd 1

19/01/2016 15:19

130167 -VS -LightingSystems -Lighting -Technical handbook valeoscope -EN.indd 1

19/01/2016 14:58

Transmission Systems

Transmission Systems

Transmission Systems

Transmission Systems Dual Mass Flywheel

Air Conditioning Ref: 998321 Transmission Systems

Lighting Systems Ref: 998542 Transmission Systems

Clutch Hydraulics

KIT4P Conversion kit

Self Adjusting Technology (S.A.T.) High Efficiency Clutch (H.E.C.)

Product focus Self Adjusting Technology (S.A.T.) High Efficiency Clutch (H.E.C.) Transmission Systems

Transmission Systems

Clutch Hydraulics

KIT4P Conversion kit

Dual Mass Flywheel

Transmission Systems

Transmission Systems

Transmission Systems

Transmission Systems Dual Mass Flywheel

Product focus KIT4P Conversion kit

Clutch Hydraulics

Self Adjusting Technology (S.A.T.) High Efficiency Clutch (H.E.C.)

valeoscope

valeoscope

valeoscope

a b c

a b c

a b c

a b c

Product focus

Product focus

Product focus

Prod

998121 -VS -TransmissionSystems -ClutchHECSAT -Porduct focus valeoscope -EN.indd 1

19/01/2016 15:05

998123 -VS -TransmissionSystems -ClutchHydraulics -Product focus valeoscope -EN.indd 1

19/01/2016 15:07

998102 -VS -TransmissionSystems -ClutchKIT4P -Product focus valeoscope -EN.indd 1

19/01/2016 15:00

Transmis KIT Conversio Transmission Dual-Mass Fl Ref: 998120 998120 -VS -TransmissionSystems -Dual-MassFlywheelDMF -Product focus valeoscope -EN.indd 1

Transmission Systems

Transmission Systems

a b c Transmission Systems Clutch HEC-SAT Ref: 998121 998123 -VS -TransmissionSystems -ClutchHydraulics -Product focus valeoscope -EN.indd 1

998102 -VS -TransmissionSystems -ClutchKIT4P -Product focus valeoscope -EN.indd 1 Transmission Systems Clutch Hydraulics Ref: 998123

Clutch Hydraulics a b c 998120 -VS -TransmissionSystems -Dual-MassFlywheelDMF -Product focus valeoscope -EN.indd 1 Transmission Systems Clutch KIT4P Ref: 998102

Self Adjusting Technology (S.A.T.) High Efficiency Clutch (H.E.C.) Product focus a b c

valeoscope

valeoscope

valeoscope

valeoscope

a b c

Product focus

Product focus

Product focus

998121 -VS -TransmissionSystems -ClutchHECSAT -Porduct focus valeoscope -EN.indd 1

19/01/2016 15:05

19/01/2016 15:07

19/01/2016 15:00

19/01/2016 15:02

valeoscope Transmission Systems Clutch HEC-SAT Ref: 998121 Transmission Systems Clutch HEC-SAT Ref: 998121 Product focus a b c 998121 -VS -TransmissionSystems -ClutchHECSAT -Porduct focus valeoscope -EN.indd 1 19/01/2016 15:05

valeoscope Transmission Systems Clutch Hydraulics Ref: 998123 Transmission Systems Clutch Hydraulics Ref: 998123 Product focus a b c 998123 -VS -TransmissionSystems -ClutchHydraulics -Product focus valeoscope -EN.indd 1 19/01/2016 15:07

valeoscope Transmission Systems Clutch KIT4P Ref: 998102 Transmission Systems Clutch KIT4P Ref: 998102 Product focus a b c 998102 -VS -TransmissionSystems -ClutchKIT4P -Product focus valeoscope -EN.indd 1 19/01/2016 15:00

valeoscope Transmission Systems Dual-Mass Flywheel DMF Ref: 998120 Transmission Systems Dual-Mass Flywheel DMF Ref: 998120 Product focus a b c 998120 -VS -TransmissionSystems -Dual-MassFlywheelDMF -Product focus valeoscope -EN.indd 1 19/01/2016 15:02

Diag & Fit

valeoscope

valeoscope

a b c

a b c

a

Product focus

Product focus

Diag & Fit

998121 -VS -TransmissionSystems -ClutchHECSAT -Porduct focus valeoscope -EN.indd 1

19/01/2016 15:05

998123 -VS -TransmissionSystems -ClutchHydraulics -Product focus valeoscope -EN.indd 1

19/01/2016 15:07

998102 -VS -TransmissionSystems -ClutchKIT4P -Product

Transmission Systems Clutch HEC-SAT Ref: 998121

Transmission Systems Clutch Hydraulics Ref: 998123

Trans Clutch Ref: 9

Braking Systems

Brake pad fault assessment

Braking Systems

Diag & Fit

Brake pad fault assessment

Find your valeoscope library on: https://valeoservice.cld.bz/ValeoScope

Braking Systems

Diag & Fit

Brake pad fault assessment

valeoscope

hl n

Diag& Fit

957100 -VS -TruckBrakingSystems -BrakePadFaultAssessment -Diag&Fit valeoscope -EN.indd 1

19/01/2016 14:59

Braking Systems Brake pad fault assessment

Truck Brake Pad Ref: 957100

7

valeoscope

hl n

Diag& Fit

957100 -VS -TruckBrakingSystems -BrakePadFaultAssessment -Diag&Fit valeoscope -EN.indd 1

19/01/2016 14:59

Truck Brake Pad Ref: 957100

valeoscope

hl n

Diag& Fit

4

Assistance Systems and Visibility Systems. Together, these 4 Business Groups comprise 16 Product Groups and supply both the Original Equipment (O.E.) market and the aftermarket. Rotating machines products portfolio is part of Valeo’s Powertrain Systems Business Group. Valeo, the Electrical Systems specialist

Valeo is an automotive supplier, partner to all automakers worldwide. As a technology company, Valeo proposes innovative products and systems that contribute to the reduction of CO 2 emissions and to the development of intuitive driving. Valeo is ranked among the world's top automotive suppliers. Valeo consists of 4 Business Groups: Powertrain Systems, Thermal Systems, Comfort and Driving

From original equipment leadership to aftermarket excellence Valeo developments always define the trends for the future! l More than 100 years of experience at the heart of automotive innovation l The best quality products mastering the highest technical specifications l Strong Market position with 180’000 parts produced daily

i-StARS + Power modules and controller

8

5

The quest to reduce CO 2 The challenge for the automotive industry

Since 2000, the quest for reduced CO 2 emissions has led to the introduction of several new technologies. One of them is the Stop-Start; it automatically shuts down and restarts the engine to reduce the amount of time the engine is idling, thereby reducing fuel consumption and emissions. This is most advantageous if you spend a significant amount of time waiting at traffic lights or frequently get stuck in traffic jams. This feature is present in hybrid electric vehicles, but predominantly appears in conventionally-powered vehicles, so-called micro- hybrids.

All countries regulate now CO 2 emissions, triggering similar evolutions on powertrains all over the planet. From StARS (2003) to ReSTART (2010), i-StARS (2010), i-StARS-2nd generation (2011), i-StARS- 3rd generation (2017) and further generations and forthcoming 48V E-machines, Valeo develops solutions to cope with car makers targets.

Reduction of CO 2

emissions

90 110 130 150 170 190 210 230 250 270

g CO2 /km I D L I N G G E T S Y O U N O W H E R E

USA

China

Europe

Japan

105 117 95

109

2000

2005

2010

2015

2020

2025

12V

12V

12V

48V

Valeo StARS

ResTART

i-StARS Gen 2

i-BSG

12V

12V

9

i-StARS

i-StARS Gen 3

6

Homologation cycles

Vehicles are all tested for emissions through standard procedures before being type-approved (authorised for sale). Performances are measured with a test car running on a chassis dynamometer. However, test methods, including test cycles (i.e. vehicle running patterns) vary among countries and regions. The test cycles simulate a range of driving conditions, at highway speeds and at speeds more typical of urban driving. To a new Worldwide Harmonized Light Vehicle Test Procedure (WLTP) by Sept. 2017 The World Forum for Harmonization of Vehicle Regulations of the United Nations Economic Commission for Europe (UN/ECE/WP29) has brought governments and car makers together to define a new test procedure to be adopted around the world.

The new WLTP cycle (Worldwide Harmonized Light Vehicles Test Procedure) was developed on the basis of driving data gathered from around the world, it covers driving cases from urban traffic to highways. Benefit from more vehicle dynamics to recover energy In contrast to the current NEDC (New European Driving Cycle), the WLTP test procedure is much more dynamic since it has many more acceleration and braking cycles than its predecessor it promotes architectures implementing energy recovery as the Mild-Hybrid.

NEDC - European cycle versus WLTP - new harmonized cycle Lessstopeventsandmorebrakingphase’s favorsenergyrecoveryfeatures innewvehicleapplications NEDC - European cycle versus WLTP - new harmonized cycle

10 20 30 40 50 60 70 80 90 100 110 120 130 140 10 20 30 40 50 60 70 80 90 100 110 120

NEDC Speed profile (km/h)

10 20 30 40 50 60 70 80 90 100 110 120 130 140 10 20 30 40 50 60 70 80 90 100 110 120 0

Percentage of drive mode

NEDC - European cycle versus WLTP - new harmonized cycle

Urban Extra-urban NEDC Speed profile (km/h)

Perce

NEDC 2007

25.1

15.5

37

22.4

Extra-urban

Urban

Braking energy recovery systems takes advantage of deceleration phases to harvest electrical energy and charge energy packs, this energy is later used for devices using the board net electrical power or for systems that helps the vehicle during transient accelerations. Speed (km/h) 0

NEDC 2007

25.1

1

WLTP

13.3 41.5

3

42.2

WLTP

13.3

0%

20% 40% 60% 80% 100%

Speed (km/h)

ew harmonized cycle

0%

20%

Decel

Cruise Accel

Stop

D

Stop

0 100 200 300 400 500 600 700 800 900 1000 1100 1200

(20mn)

Time (seconds)

0 100 200 300 400 500 600 700 800 900 1000 1100 1200

Percentage of drive mode

(20mn)

Time (seconds)

NEDC 2007

25.1

15.5

37

22.4

WLTP Speed profile (km/h)

WLTP Speed profile (km/h)

WLTP

13.3 41.5

3

42.2

0%

20% 40% 60% 80% 100%

Speed (km/h)

Decel

Cruise Accel

Stop

Speed (km/h)

Urban

Peri-urban

Road

Highway

(20mn) 1100 1200

0

Urban

Peri-urban

Road

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800

0

10

(30 mn)

Time (seconds)

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 150

Time (seconds)

Stop-start function is a concrete answer to reduce CO 2 emissions and fuel consumption adapt the Stop-Start function to a given situation and according to many parameters. A major parameter is the engine temperature. A certain percentage of fuel is consumed to overcome friction in powertrain, to enhance vehicle efficiency a reduction of friction is crucial; to achieve this the oil viscosity (temperature) must be optimal. As major part of the pollutants is emitted after starting the vehicle, the very first action is to reduce the oil viscosity by accelerating the engine warm up, the ten first minutes are crucial. Bringing vehicle oil to an optimal operating temperature, and maintaining it is the first step to reducing fuel consumption and CO 2 emissions. Some techniques help in reaching optimum oil operating temperatures, the most common and historical technique is to bypass the coolant circuit radiator, this is part of the role of the engine cooling loop thermostat. Oil coolers are common on engine, they are able to work in both directions, having the ability either to cool the oil but as well to heat the oil by exchanging heat with the coolant, they are as well used to speed up the oil temperature raise.

7

What are Stop-Start benefits? The reduction of fuel consumption, greenhouse gases and pollutant emissions is one of the major challenges that the automotive industry faces today. Automakers are making massive R&D investments in a bid to improve the efficiency of their engines. But progress is only made in small steps. Since, in city driving, vehicles are at a standstill for almost 35% of the time, during which the engine idles needlessly, the benefits of the Stop-Start system are quite obvious. This system switches off the engine when the vehicle stops, at a traffic light, for example, and starts it up again as soon as the driver asks for power. The benefits of Stop-Start systems are highly depending on the driving cycle that is considered. Considering the only urban portion of the NEDC fuel economy reach 15%, rising to 25% in real conditions of traffic jam. A common question from end customers on the Stop- Start function efficiency relates to some thoughts on fuel over consumption when restarting an engine. Internal combustion engine are still governed by the same thermodynamic laws and restarting a machine always require energy, but enginemanagement have notably evolved, allowing today some advanced injection processing to speed up the cranking phase. This is further completed by complex strategies to On a global NEDC cycle, Stop-Start systems represent between 4 to 5% fuel economy.

Stop-Start systems are only activated after engine heat-up completion.

11

Stop-Start is at the heart of car makers' strategy

VALEO POWERTRAIN OFFERS OE INNOVATIONS AND POSITIONS

VALEO POWERTRAIN SYSTEMS EQUATION

INNOVATION WAVES

- CO

2 - NOX - PARTICLES + REGULATIONS  & LOCAL POLICIES

ELECTRIFICATION HIGH POWER

ELECTRIFICATION

ELECTRIFICATION MEDIUM POWER 12V + 48V

SMART ENGINES & TRANSMISSIONS

2016

2019

2022

2025

Source: investor meeting sept. 2016

Market is driven by the global regulation, which, with the recent Euro6.2 standard , imposes a maximum 95 g/km CO 2 emission by 2021 in Europe.

2021 Electrical Car Park equipment

5% 2%

Conventional Micro Hybrid

2017

World’s first aircooled 48V Belt starter generator with DCDC converter

Mild-Full Hybrid

48v

36%

57%

2016

World’s first Electric Supercharger on Audi SQ7

2012

World’s first 12V Mild Hybrid on Nissan Serena

2016 Electrical Car Park equipment

Conventional Micro Hybrid

1%

12%

Mild-Full Hybrid

2008

Invention of 48V Mild Hybrid « Hybrid4All »

87%

2004

World’s first 12V Stop-Start. More than 3 MU produced since 2004

12

8

Micro-hybrid stop-start system at a glance Micro-Hybrid architectures Micro-Hybrid vehicles are able to automatically manage stop and start phases according to traffic transient stops (traffic lights, traffic jam) while optimizing comfort for the driver.

Valeo technologies for Micro-Hybrid applications

Valeo launched its first Micro hybrid solution on the Citroen C3 in 2004, since this first development Valeo designed new solutions (3 generations) to cope with the massive deployment of this technology over the automotive market. ●● StARS – S tarter A lternator R eversible S ystem ●● i-StARS – I ntegrated S tarter A lternator R eversible S ystem ●● ReStART- R einforced S tarter While ReStART is a Stop-Start solution keeping separate starter and alternator functions, the Valeo StARS takes benefit of combining the starting and charging features in a common reversible machine (starter-alternator), it actuates the engine crankshaft via a tailor made belt drive during the start phase and switches to the charging mode as soon as the engine is running. The key advantages of StARS are: Valeo is the only automotive supplier to offer two Stop-Start solutions for the Aftermarket.

Valeo offers two complementary options to the Micro-Hybrid Stop-Start market

Engine

Engine front end

To drive train

Belt driven reversible machine

Reinforced starter

●● Quick cranking phase ●● Silent cranking phase ●● High electrical efficiency

13

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Valeo StARS system

StARS starter-alternator can be adapted to any automaker Micro-Hybrid strategy that takes into account a multitude of parameters related to the engine, clutch, gearbox, brakes or other comfort and safety equipment. Thanks to the belt driven technology, StARS allows to restart the engine even while processing to a stop, either if the driver unexpectedly changes his mind or if the system requires to be restarted for any reason (electrical energy needs, cabin cooling needs…). Valeo’s StARS was rewarded with the 2006 PACE Award, the Grand Prix of the EPCOS/SIA Jury and the 2004 Engineering Award, distinctions that underscore the keen interest shown by the automotive industry in this solution.

Starter Alternator Reversible System, a winning technology

Valeo StARS solution combines both alternator and starter functions in a unique machine.

In starter mode, the engine is started immediately and silently via the belt drive. For further savings the alternator mode features a new rectifying technology improving the electrical efficiency (less fuel required to charge the battery). These two decisive advantages make StARS the ideal product to achieve fuel savings and improve comfort, doing away with conventional discomfort of stops and restarts phases.

2004: Valeo offers the very first Belt driven Micro-HybridStop-Start to the market

14

System overview The first generation of StARS combines a machine, a power controller and a 3 phase power harness. StARS is a 14V machine, it is compatible with conventional board-net voltages.

The StARS machine In the first generation of StARS the machine embeds a very tiny amount of electronics, the essential being in the external power controller. Similarly to an alternator structure the StARS rotating machines is a synchronous machine with a claw rotor. The machine is composed of: ●● A poly-V pulley ●● A rotor ●● A rotor angular position sensor ●● A stator ●● A brush holder

StARS - the first generation of Valeo starter alternator system

The power controller reacts according to numerous sensors and commands conditions from the vehicle; one connector is dedicated to power stimulus for the machine and one to control signals. StARS in the electrical system Can Bus

●● A fan system ●● Ball bearings ●● Connectives systems (3 phase power and control signals) ●● Housing and brackets

StARS in the electrical system Battery

Can Bus

3 phases cable

Engine Management unit

StARS power controller

StARS machine

Airbag Management unit

(1)

Battery

ESP Management unit

3 phases cable

StARS machine Control & status signals

Control & status signals

Engine Management unit Body Controller unit

StARS power controller

Front Bracket

Airbag Management unit

(1)

Interpole Magnet

Lin Bus

ESP Management unit

Control & status signals

Control & status signals

Body Controller unit

Stator Coils

(1) Lin Bus on some StARS applications

Lin Bus

Stator Iron Stack

Pulley

(1) Lin Bus on some StARS applications

Fan

Collector Rings

Rear Bracket

Front Fan

Brushes

Cover

Rotor Bobbin

Claw Pole

Magnetic Target

For synchronization purpose, the StARS machine embeds a rotor angular position sensor, allowing the power unit to precisely control starter mode operations.

Hall Effects Sensors

3 Phase Terminal

15

The StARS controller The power controller is the brain of the system; it controls all working modes according to the vehicle status. The power controller is composed of: ●● A micro-controller board ●● A power board with MOSFET-type transistors ●● A heat sink ●● A housing ●● Connective systems (power and signal) The power controller can be located in the engine compartment, it withstands underhood thermal environmental constraints and generally located in the wheel arch area.

StARS power controller

Phase 1

Phase 2

The three phase power cable makes the link between the machine on the engine block and the power controller on the wheel arch.

Phase 3

StARS - in alternator mode In alternator mode, the controller collects current from the stator phases, and converts the alternate signals with Metal Oxide Semiconductor Field Effect Transistors (MOSFET’s) via synchronous rectification. The so called synchronous rectification also known as active rectification replaces the conventional power diode rectifier for a much higher efficiency.

D

voltage

+

Output

Control

G

0

voltage

+

time

Input

-

0

time

S N-Channel Mosfet transistor symbol, with its inherent diode between drain and source,...

-

The basics of a synchronous rectifier bridge

16

The use of MOSFET’s to achieve the rectification function conventionally performed by diodes, improves efficiency, thermal performance, power density, and reliability. Higher efficiencies can be achieved by synchronously switching the power transistors to emulate diodes, taking advantage of the transistors’ low conduction losses. Synchronous switching means getting a transistor to turn on and off according to the polarity of the AC waveform so it acts as a rectifier. Choosing high performance MOSFET transistors reduces the forward voltage drop to a fraction of what any diode can achieve. Hence, the synchronous rectifier will have a much lower loss than a diode, improving the alternator’s efficiency. Synchronous rectification is one of the reasons for the outstanding 82% efficiency of the StARS starter alternator, which is a full 10% higher than the best conventional alternators on the market.

For a higher efficiency, conventional rectifier diodes are replaced by MOSFET transistors.

Implemented in Valeo StARS systems, the synchronous rectification allows a CO 2 reduction of about 2 g/km.

Active rectifier losses 70w@200A

Diode rectifier losses 350w@200A

Efficiency + 8 points

140 120 100

D

A

G

MOSFET synchronous rectifying Reduces voltage drops by factor of 5 versus diodes Generates less heat Gain in Amps.@Idle RPM Gain in efficiency by 8 points CO 2 reduction of about 2g/km

C

S

80 60 40 20 0

Current (A)

0,20V

1,00V

0

0,40V 0,60V 0,80V

1,20V

V drop (losses,...)

Thanks to their micro-electronic structure MOSFET’s are able to almost eliminate the voltage drop during current rectifying: 0.2 V instead of 1.0 V @200A

Given that: power equals voltage times current, power losses inside the bridge are divided by factor 5.

17

MOSFET transistors can be considered as power switches, they are activated (open or closed) in special sequences according to the angular position of the rotor.

For a three phase rectifier six transistors are arranged in three branches, synchronous rectifying is achieved by connecting the appropriate stator phase polarity to the battery positive or negative terminal.

The stator delivers power

Phase U

+ -

Phase V

0 5 10 15 20

Phase W

0

5 10 15 20

0 5 10 15 20

Three phases rectifier

3 x Stators phases after synchronous rectifying

3 x Stators phases

When connected to the battery the three phases rectified signals combine, resulting in a quasi continuous DC signal.

18

StARS - in starter mode The same MOSFET bridge is used to control the machine in alternator and starter modes. In alternator mode the transistor bridge receives power from the stator phases, in starter mode it is the opposite situation. In starter mode, the machine behaves as a three phase motor, it reacts to interactions between the stator and the rotor electromagnetic forces and rotates accordingly.

The MOSFET bridges stimulate the stator phases generating a rotating field and thus torque to the rotor. The rotor angular position and speed, as well as the phase currents are monitored and processed to optimize the machine torque output.

Temperatures are monitored to take benefit from a maximum energy conversion.

The stator receives power

Phase U

+ -

Phase V

0 5 10 15 20

Phase W

StARS power stage in starter mode.

As in the alternator mode, in starter mode the rotor coil is energized. The power unit drives the stator phases according to a hall-effect magnetic position

sensor that gives at any time the rotor relative position from the stator, knowing this relative position is crucial to the machine performance, notably for the torque output.

PHASE 1

PHASE 1 PHASE 2 PHASE 3

Stator

Rotor

PHASE 3

PHASE 2

Strator and rotor electromagnetic forces interact creating a rotation

19

PHASE 1

PHASE 1 PHASE 1

PHASE 1

The position sensor consists in three devices (H1, H2, H3), they are each 120° shifted and require a high positioning accuracy for the machine to deliver the appropriate torque output with minimized ripple. The MOSFET half bridges are activated in multiple commutation sequences to create a 360° rotation. ●● Stator phases are excited two by two in a 360° sequence, triggering a rotating field ●● The rotor aligns to the stator magnetic field for each new sequence generating torque ●● The torque amplitude varies according to the position of the rotor, it is higher at each half bridges commutation and stator/rotor alignment ●● The machine output torque is maximized thanks to advanced control timings and communications overlapping on the MOSFET half bridges. In StARS, the MOSFET bridge is capable of delivering a 600A current, generating enough torque to drive the internal combustion engine immediately and at higher revs than a conventional starter.

H2

H2

H2

Hall effect position magnetic sensor Hall effect position magnetic sensor Hall effect position magnetic sensor

Hall effect positi n magnetic sensor

H2

H1

H1

H1

H1

H3

H3

H3

H3

PHASE 3

PHASE 3 PHASE 3

PHASE 3

PHASE 2

PHASE 2 PHASE 2

PHASE 2

Three position sensors, 120° shifted

Maximum torque

Output torque

Maximum torque

Output torque

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 3

PHASE 2

PHASE 3

PHASE 2

PHASE 3

PHASE 2

PHAS

Stator phase commutation

PHASE 3

PHASE 2

PHASE 3

PHASE 2

PHASE 3

PHASE 2

Stator phase commutation

20

START

The machine can start the engine in less than 0.4 seconds. As soon as the engine has started the StARS immediately switches back to the alternator mode.

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 1

PHASE 3

PHASE 2

PHASE 3

PHASE 2

PHASE 3

PHASE 2

HASE 2

PHASE 3

PHASE 2

PHASE 3

PHASE 2

PHASE 3

PHASE 2

sequences for a 360° cranking torque ion sequences for a 360° cranking torque

Time

Time

21

10

Belt drive designs

Alternator

Whatever their type and technologies, modern belt drives must comply with the following requirements: For more performance ●● Automatic and constant tensioning ●● Compensation of the belt drive tolerances ●● Maximized torque transfer ●● Limitation of slippage For higher lifetime ●● Limitation of peak dynamic forces in the drive ●● Limitation of belt wear ●● Compensation of belt elongation (notably in heat conditions) Belt drive are governed by power needs, rotational speeds, torque transmission, efforts, dynamics and resonant phenomenons that makes them quite complex to design. Pulleys diameters are defined according to components working conditions for some strategic rpm ranges as: ●● engine idle ●● cranking ●● maximum engine rpm Torque transmission is done by friction of the belt on the pulleys, to secure this, a certain portion of the pulley must be wrapped by the belt, this critical parameter is called the wrap angle. The crankshaft pulley is at the heart of the belt drive, in belt driven hybridized architectures it is a torque source during electrical charge or recovery sequences and a torque consumer in torque assist or boost events. As a torque hub the crankshaft pulley has a large wrap angle. For more comfort ●● Limitation of noise

Idler

ω

A/C compressor

Crankshaft

The basics of a belt drive

The wrap angle The wrap angle is the angle of contact between the belt and a pulley, it is defined according to numerous parameters as: ●● Engine front end layout and constraints ●● Components positions ●● Torque to be transmitted per pulley ●● Belt type The wrap angle have a huge impact on the belt drive complexity, requiring in some cases to add multiple idlers to properly wrap the belt on more sensitive pulleys notably for BSG machines where the pulley diameter limits the belt contact surface. In static conditions (no rotation) the pulley is submitted to a load that is imposed by the belt tension (T0) on both sides of the wrap angle.

22

t Sliding area Most important parameters to transmit higher torques: ●● increase the belt wrap angle on the pulley ●● increase the belt preload to have higher contact pressure area to reduce belt slippage ●● increase the number of ribs on the belt to get a higher friction coefficient The torque transmission generates belt tension fluctuations (slack span & tight span) which can be critical if the slack span belt tension goes too low, automatic tensioners are required to compensate this. When the torque demand gets too high and generates the complete slip on the belt, the “functional slip” becomes “complete slip” which is critical as it leads to a total loss of torque transmission. Automatic tensioners Automatic tensioners maintain a constant belt tension in the slack span over the engine operating range, they are designed to: ●● To assure a minimal belt preload in any boundary conditions - engine geometrical tolerances - ambient temperature (cold or hot) - belt conditions (new belt, aged belt) ●● To optimize the system lifetime (lower belt preload than static tensioner) ●● To damp some belt vibrations / engine irregularities Tensioners are made of a stiffness element to apply force on the belt in any conditions and a damping element to get a smooth dynamic system behavior, they can be designed with a symmetric or an asymmetric damping behavior, with a mechanical damping function or an hydraulic damping function. High torque transmission H T C In dynamic conditions the warp angle is the seat of some phenomenon at the surface of the pulley, where the belt partially sticks and slips. As the belt is a reversible elastic body, the length of the belt is getting longer when the internal force is changing from the slack span to the tight one. It generates micro-movements of the belt section which is running on the pulley ; this phenomena is called : “functional slip”. As the torque demand increases, the portion of the slip section to the wrap angle increases, leaving less space for the belt to stick and convey torque to the pulley.

H

Wrap angle

H = hubload

T

T

0

0

T 0 = static belt tension

The wrap angle: contact zone between the belt and the pulley

H

Sticking area

Sticking area

Sliding area

t

T

C

Low torque transmission

A naturel sliding is inevitable but it must be limited

H

Sticking area

Sliding area

ng area

t

T

C

High torque transmission

23

11

Belt Starter Generator drives To new Front End Accessory Drive Conventional belt drives do not comply with Stop- Start torque transmission needs, they are not able to maintain enough driveability between the belt and the pulley in cranking conditions requiring adaptations: in the belt layout, in the tensioner and in the belt type. The figure below illustrates the slippage phase that occurs if using a conventional tensioner in a cranking phase, a long slippage event occurs prior the drive is able to put in motion the engine crankshaft.

Starting by the StARS Micro-Hybrid and followed by Mild-Hybrid belt drive generations, all Belt Starter Generator drives (BSG) differ from conventional Front End Accessory Drive (FEAD) in several ways and are designed to: ●● Delivering torque to the crankshaft when starting ●● Delivering torque to the crankshaft in torque assist phases ●● Absorbing torque from the crankshaft when producing electricity ●● Absorbing torque from the crankshaft in the “engine stalling help” mode ●● Absorbing torque from the crankshaft in electrical recovery phases ●● Supporting peak dynamic forces Considering the maximum torque during these cycles: ●● Belt performances are made higher ●● Wrap angle is increased Considering belt tension fluctuations during start and charge modes (slack span & tight span), a new tensioner concept is required to guarantee power transmission to the engine crankshaft and from the engine crankshaft without slippage.

Conventional tensioning

Starter Alternator

500

Belt Starter Generator rotation

400

Crankshaft

Starter Alternator

500

300

400

Crankshaft

200

300

Slippage

200

100

Slippage

100

000

Rotary speed (reduced) in U/min. 000

Rotary speed (reduced) in U/min.

1

0

1

0

Time in sec.

Time in sec.

A unique conventional tensioner does not allow Sto Belt Starter Generator rotation A unique conventional tensioner does not allow Stop-Start features

Starter Alternator

500

400

Crankshaft

Belt Starter Generator rotation

300

200

Slippage

100

24

000

Rotary speed (reduced) in U/min.

1

0

Time in sec.

A unique conventional tensioner does not allow Stop-Start features

Engine acyclisms The functioning of Integral Combustion Engines is characterized by the alternation between the phases of compression and combustion. The Cyclic Variations of the pressure inside the cylinder cause rotational speed variations, these variations are called acyclisms. Acyclisms cause a non-uniform rotation speed; they are also defined as torsional vibrations. This succession of acceleration and decelerations in the rotation-cycle is transmitted to the belt drive, as the auxiliaries inertia do not allow to follow this sudden deceleration a counter torque applies to the belt drive, leading to slippage.

Tailored belt drives are mandatory to perform Micro- Hybrid and further Mild-Hybrid function with Belt Starter Generator machines, their design depends on: ●● Hybridization level (recovery, torque assist, boost..levels) ●● Engine capacity (torque level to crank the engine) ●● Engine torsional vibrations ●● Engine driveline (Dual mass Flywheels architectures impact crankshaft front end rotational vibrations due to a lower primary wheel inertia) ●● Engine front-end layout ●● Dynamic loads

A dual tensioner secures the slack side of the drive and avoids belt slippage With dual t nsion r

Starter Alternator

500

400

300

With dual tensioner

200

Crankshaft

100

Crankshaft

Rotary speed (reduced) in U/min.

Auxiliary pulley

000

1

0

Time in sec.

400

-200 -100 0 100 200 300

Engine irregularities expressed in torque variation (Nm)

Engine irreg in torque var

Torque (Nm)

0

90

180

270

360

450

540

630

720

Crankshaft angle (°)

0.1

0.05

0

Engine irregularities expressed in angular displacement (deg)

Engine irreg in angular di

-0.05

-0.1 Displacement (°)

-1.15

0

90

180

270

360

450

540

630

720

25

Cranshaft angle (°)