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  • Powertrain & Thermal Systems

    Flins 15 Dcembre 2016 1Property of Valeo Duplication Prohibited

    lectrification des fonctions et des auxiliairesFlins - 15 Dcembre 2016

    L'lectrification et composants 48V des fonctions moteur et auxiliaires

    O. COPPIN N. DEVIENNE

  • Agenda

    Drivers for hybridization

    Low voltage Hybrid systems and functions

    Alternative boosting : electric supercharger

    Function electrification

    Flins 15 Dcembre 2016 2Property of Valeo Duplication Prohibited

    Function electrification

    Low voltage Road-Map

    Conclusion

  • Driver for hybridization : CO2 regulationsMain issue of hybrid / electric: COST!

    China 2020(cars only):106

    Flins 15 Dcembre 2016 3Property of Valeo Duplication Prohibited

    Diesel : the upper limit customers are willing to pay To develop in mass-market, hybrids need to be cheaper : Why 12V+12V and 48V make sense

  • Powertrain Solutions for CO23 main technical Areas

    Flins 15 Dcembre 2016 4Property of Valeo Duplication Prohibited

    Internal Combustion

    Engine Downsizing

    Turbocharger/SuperchargerGasoline Direct InjectionGasoline Cooled EGRVariable Valve ActivationThermal management

    Electrification

    Stop-Start Mild Hybrid Full Hybrid Plug-in Hybrid Range Extender Battery Electric Vehicles Energy management

    Downspeeding &

    Automation

    Double Clutch Transmission Automatic Early lock-up Downspeeding

    1 2 3

  • Hybrid Architectures

    P2 P4P4

    P4

    P0

    P3

    P0 / P1 P2 P4P3

    P1

    Flins 15 Dcembre 2016 5Property of Valeo Duplication Prohibited

    E-motor linked to ICE

    E-motor decoupled from

    ICE, at same speed

    P0 / P1 P2E-motor in

    driveline or in rear axle or in

    wheels

    P4E-motor

    decoupled from ICE, at a speed

    multiple than ICE

    P3

    48V can address all hybrid architectures and enhance hybrid functions benefits48V can address all hybrid architectures and enhance hybrid functions benefits

  • Functions availability

    P0 Belt 12V P0 Belt

    12V + 12V

    P0 Belt 12V + 12V

    + eSC

    P0 Belt 48V(+ eSC)

    48V P2/P3/P4

    Cold start o o o o / o / (P2) Change of Mind Stop & Start High Efficiency generator Durability (1mcy) Comfort Start Stalling help Coasting o / Regenerative braking o

    Flins 15 Dcembre 2016 6Property of Valeo Duplication Prohibited

    o : Limited : Possible

    : Impact on fuel savings

    Regenerative braking o Torque Assist o o Torque Monitoring o o Downspeeding Engine Dowsizing ZEV o / Electrical Take off o /

    Voltage increase will enhance hybrid functionsP2, P3, P4 architectures increase hybrid energy management benefits

    Voltage increase will enhance hybrid functionsP2, P3, P4 architectures increase hybrid energy management benefits

  • Why 48V Hybrid is affordable

    Low voltage Small battery Cheap battery

    Belt Starter-Generator

    All-in-one : Just replaces the alternator with integrated inverter

    Standard powertrain architecture

    Limited power : air cooling possible if

  • Peugeot 308 48 Volt Electric AWD : Essencyele.

    Association of a 48V P0 belt machine and a 48V electric rear axle

    All Hybrid functions including electric driving

    Cost effective thanks to 48V

    P4 hybrid architecture efficiency

    Up to 22%* CO2 emission reduction on NEDC, up to 16%* WLTP

    AWD mobility function as added value for end customer.

    Funded project

    Flins 15 Dcembre 2016 8Property of Valeo Duplication Prohibited* Valeo estimate based on simulation, will vary per vehicle application

  • Alternative Boosting : efficiency analysis

    17,4

    100 > 100100 > 82,6

    Mechanical supercharger Electrical supercharger

    Flins 15 Dcembre 2016 9Property of Valeo Duplication Prohibited

    With e-Supercharger there is no friction while boosting.

    Energy is free while recovered during braking

    High mechanical losses, only 82% of generated torque goes to the wheels

    No Mechanical losses. 100% of the generated torque is transferred to the wheels

  • Interest of alternative boosting : efficiency

    5 kW

    Hybrid system Electrical supercharger

    25kW25kW25 kW

    Flins 15 Dcembre 2016 10Property of Valeo Duplication Prohibited

    To get 25kW on the wheels, need ~5 kW on the air thanks to combustion COP.

    With 300Amps limit , 48V is far enough

    To get 25kW on the wheels, need ~25 kW from the e-motor.

    With 300Amps limit , 100V necessary

    With the electric supercharger there is fundamentally efficiency benefit linked to combustion COP

    For the same power at wheels, the hybrid voltage can be reduced from high voltage to 12V or 48V: the electric system, including batteries, is then far

    cheaper.

  • 26

    Electric Supercharger = instantaneous response

    16

    18

    20

    22

    24B

    ME

    P (

    bar

    )26

    Turbo engine

    Electric supercharger

    after 0.5sTurbo after 2.0s

    Turbo after 1.0s

    Flins 15 Dcembre 2016 11Property of Valeo Duplication Prohibited

    8

    10

    12

    14

    BM

    EP

    (b

    ar)

    500 1500 2500 3500 4500 5500 6500Engine speed (RPM)

    Naturally aspirated engine

    Turbo after 0.5s

    The higher the downsizing, the longer the turbo lag @ low RPM. The turbo isunable to compensate the lag. Response time is the key parameter

  • Renault Fluence: SURAL-HYSupercharging system for hybrid gasoline

    engines with high downsizing

    Integration of 1.2L

    Electric supercharger3 kW, 12 Volts

    Funded project

    Flins 15 Dcembre 2016 12Property of Valeo Duplication Prohibited

    Integration of 1.2L Renault turbo engine

    with the Electric Supercharger

    Design and integration of a larger Turbo to achieve

    100kW / L

    Partial 'free' power boost, symmetry braking phases: energy recovery

    and energy use with 12V

    Engine downsizing and downspeeding thanks to eSC integration

    12V NiZn battery eSC dedicated Gearbox

    downspeeding(15%)

  • More Power

    Electric Supercharger 3 main applicationsLess pollutantsBetter Fuel Efficiency

    Flins 15 Dcembre 2016 13Property of Valeo Duplication Prohibited

    Audi RS5 TDI 386HP

    Volvo eDrive 450HP

    Valeo NA Democar 8% FE

    Ricardo HyBoost 20% FE Valeo-FEV : Euro6 w/o SCR

    48V 12V Diesel

  • Electrical board net : modular building 12V -> 48V

    12V Battery 1

    12V Sensitive

    Loads

    12V NON Sensitive

    LoadsStarter

    Optional Piloted switch

    12V Battery 2

    12V clean network12V regen network

    12V + 12V Basic Set

    Reversible Machine Starter + Alternator 12V

    Optional Piloted switch

    12V clean network12V regen network

    Reversible Machine Starter + Alternator 12V 12V NON

    Flins 15 Dcembre 2016 14Property of Valeo Duplication Prohibited

    12V + 48VStarter

    Reversible Machine 48V

    DCDC48-12 V

    eSC

    12V clean network48V regen network

    48V Battery

    12V Battery

    12V Sensitive

    Loads48V NON Sensitive

    Loads

    12V + 12V Extented Set

    12V Battery 1Starter 12V

    Battery 2

    Starter + Alternator 12V12V

    Sensitive Loads

    12V NON Sensitive

    Loads

    eSC

  • Future steps

    Develop P2, P3 & P4 48V application to enhance efficiency

    48V : a way to address low cost small electric vehicle ?

    Power level compatible with 80 to 100 km/h max

    Flins 15 Dcembre 2016 15Property of Valeo Duplication Prohibited

    Autonomy up to 100km by battery sizing

    Keep cost and component modularity with 48V hybrids

  • 12+12V & 48V Road MapFirst 12V application : Stop & Start

    60

    70

    80

    % C

    O2

    Red

    uct

    ion

    Systems CO2 gains / cost position

    Flins 15 Dcembre 2016 16Property of Valeo Duplication Prohibited

    0

    10

    20

    30

    40

    50

    60

    % C

    O2

    Red

    uct

    ion

    system cost

    STT

  • 12+12V & 48V Road Map

    60

    70

    80

    % C

    O2

    Red

    uct

    ion

    Systems CO2 gains / cost position

    48V mild hybrid : more power and more energy available

    First and easier step : belt e-machine.

    Flins 15 Dcembre 2016 17Property of Valeo Duplication Prohibited

    0

    10

    20

    30

    40

    50

    60

    % C

    O2

    Red

    uct

    ion

    system cost

  • 12+12V & 48V Road MapA better cost / CO2 gain ratio than high voltage systems

    48V : An increasing potential with boosted hybrid and power devices electrification

    A continuous extension : accessories electrification, P3/P4 hybrid architectures, new concepts.

    60

    70

    80

    % C

    O2

    Red

    uct

    ion

    Systems CO2 gains / cost position

    Flins 15 Dcembre 2016 18Property of Valeo Duplication Prohibited

    0

    10

    20

    30

    40

    50

    60

    % C

    O2

    Red

    uct

    ion

    system cost

  • 12V systems have a limit around 4 kW (~300 Amps max)

    48V board net opportunity : more power available

    8000

    10000

    12000

    Lights

    BoardFuel Pump

    ABS, CBC and DBC Actuators

    Small Power consumers

    Blower

    Fan

    BMW 750i Diesel 3.0L WLTC 40C + comfort function ON

    Flins 15 Dcembre 2016 19Property of Valeo Duplication Prohibited

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