2014-10-07-Nexteer-Valeo-meeting.pdf troy

1. October 7, 2014 I 1
Nexteer / VALEO
Meeting in Troy
October 7, 2014

2. October 7, 2014 I 2
Valeo Group : Key figures 2013
51
Research &
Development centers
12
Distribution
platforms
124
Production sites
29
Countries
74,800
Employees
Record order intake:
14.8Bn €
Sales
12.1Bn €

3. October 7, 2014 I 3
Valeo Group : Worldwide presence
3,500 Employees
7 Production sites
5% of sales*
9,965 Employees
13 Production sites
19% of sales*
37,143 Employees
56 Production sites
50% of sales*
(including Africa)
24,192 Employees
48 Production sites
26% of sales*
end 2013
* In % of OE sales

4. October 7, 2014 I 4
4 Business Groups with strong market positions
€3.4 billion Sales
(28% of Group total)
18,128 Employees
Thermal
Systems
€3.1 billion Sales
(26% of Group total)
23,012 Employees
Visibility
Systems
€3.4 billion Sales
(28% of Group total)
18,769 Employees
Powertrain
Systems
€2.3 billion Sales
(18% of Group total)
13,431 Employees
Comfort &
Driving
Assistance

5. October 7, 2014 I 5
Powertrain 2013 Key Figures
Campinas
San Luis Potosi
Troy
Chennai
Pune
Nanjing
Bursa
Basildon
Kyong Ju
Daegu
Atsugi-shi
Fuenlabrada
32 Production Sites
16Development Centers
18,800People
5Research Centers
Amiens
Ste Florine
Limoges
I‘lsle d‘Abeau
Créteil
Cergy
Étaples
Angers Sablé s/Sarthe
Gravatai
Jedeida
Shenzhen
Mondeville
Shanghai
Mondovi
Togliatti*
Czechowice
*SOP 2014
Abbeville
Cairo
Bietigheim
Wuxi
€3.4Bn 2013 sales
Drammen

6. October 7, 2014 I 6
2013 OEM Sales
2.7B€
Powertrain : A diversified Customer Base
French
Asian
Other
American German
2013 figures

7. October 7, 2014 I 7
Medium Power
eclectronics
High Power Electronics
for HEVs & EVs
Energy Conversion
Electronics
Product Group “PEL”
- CO2 Emission
Reduction
Transmission Systems
Product Group “PTR”
Automatic Transmissions
Powershift Transmissions
Manual Transmissions
Friction Materials
Hydraulic Clutch Actuation
Combustion Engine
Product Group “PCE”
EMS ECUs
Actuators & Sensors
Boost & Coolant Control
Exhaust & Air Control
Air Charging Systems
System Engineering & Transversal Innovation
- Hybrid and
Electric
- Pollutants
Emission Reduction
Electrical Systems
Product Group “PES”
Alternators
Electric Motors
Belt Starter Generator
Reinforced Starters
Starters
Powertrain Systems Business Group

8. October 7, 2014 I 8
Rio Bravo
(Mexico)
Troy
(USA)
Shenzhen
(China)
Shanghai
(China)
Cergy, Créteil
(France)
Sablé
(France)
Veszprem
(Hungary)
Front office
Development center
Plant
Mother plant = Sablé (France)
Drammen
(Norway)
Shinjuku
(Japan)
Valeo Power Electronics footprint
Deliveries possible from China (Shenzhen), Hungary (Veszprem) and Mexico
(Rio Bravo)

9. October 7, 2014 I 9
Medium Power Electronics
Product overview

10. October 7, 2014 I 10
0
20
40
60
80
100
120
140
0,00 0,20 0,40 0,60 0,80 1,00 1,20
Diode
MOS EG
VF (Volt)
I
(
Amp)
ASIC
MOS φ 1 MOS φ 2
Voltage drop at 100A @ 25°C
reduced by factor 5
 Loss reduction
Substrate
Al2O3 0,38mm
Copper 0,2mm
Bare die for driver ASIC and
MOSFET
2 phases per power module
4 MOSFETS & 1 driver ASIC
Standardization
3 power modules for 6 phases
machine
2 power modules for 3 phases
machine
EG Alternator
Voltage Drop: Mosfet vs. diods
Valeo DBC power module
with ASiC gate driver

11. October 7, 2014 I 11
Rear cover
Heat
sink
Brush
holder
Interconnector
Control module
Control ASIC
Power module
MosFets
Driver Asic
Thick copper
Lead frames
12V i-Stars
Belt Stater Generator
Rear of the machine
IML Power Module
2012/12/05 11

12. October 7, 2014 I 12
- High performance thanks to the thermal decoupling
-Common platform air & water cooled i-BSG
-Up to 12kW regen
i-BSG
Air cooled
i-BSG
Water coled
Common
power module
i-Belt Starter Generator
Mock-up
Valeo IML power module
Available mock-up

13. October 7, 2014 I 13
Current EPS product – FIRST
GENERATION
Customer #1
Sensor board
Control Board (FR4)
EMC/EMI filter
Power leadframe
Power
module
2012/12/05 13

14. October 7, 2014 I 14
EPS EDC
i-BSG
ESC
EG
i-StARS
Large product range with different mechatronics …
DBC
power
module
Same
Design
Justification
Same FMEA
Same
BOM &
schematic
Generic
Simulation
tools
Same
Test
procedures
IML
power
module
…based on shared
technologies
… designed with the same
building blocks
Power Electronics Building Block Approach

15. October 7, 2014 I 15
EPS GENERIC

16. October 7, 2014 I 16
EPS & HEPS
Valeo references:
Thyssen Krupp Presta: Mercedes S-class, BMW
Volkswagen / Audi: MLB-evo platform
JTEKT: HEPS since more than 10 years
Several million units per year

17. October 7, 2014 I 17
Unit Medium power -Rack EPS High power – Rack EPS
DC Voltage V 13,5V (6V – 27V) 13,5V (6V – 27V)
AC current A
130 (peak - 2s) – 95
(RMS)
160 (peak – 2s) – 120
(RMS)
DC current Arms 95 120
Switching frequency kHz 16 16
Temperature
with derating mode
°C -40/125 -40/125
IP external IP6k9k IP6k9k
IP ECU Motor No No
EMC Filter CISP25 class 5 CISP25 class 5
Safety concept ISO26262 (ASILD) ISO26262 (ASILD)
External EEPROM No No
Phase switch Integrated Integrated
Communication CAN or Flex ray CAN or Flex ray
Sleep Mode
Sleep Mode
(No index)
Sleep Mode
(No index)
EPS Generic Range
Main features
To cover the full EPS range

18. October 7, 2014 I 18
EPS roadmap at Valeo
EPS1 (160 A peak) EPS 3 (130 A peak) EPS 4 (130 A peak)
- Discrete control board on FR4
- DBC power module
- Electronic on chassis
- ECU assembly at Valeo
- Discrete control board on FR4
- IMS power board
- Electronic on chassis
- ECU assembly at Valeo
- Discrete control board on FR4
- FR4 power board
- Chassis removal
- ECU assembly at JTEKT
Discrete technologies are used until their maximum operating area
Mechanical parts are optimized thanks to a better process integration with the motor
103mm
125.3mm
Ø93mm
96.3mm
101.5mm
124mm
Ø93mm
54mm
117mm
117mm
Long
Short
BOM: -20% vs. Ref.
BOM: -40% vs. Ref.
BOM: -32% vs. Ref.
EPS 2 (140 A peak)
Reference BOM

19. October 7, 2014 I 19
BBF
DBC bank
+ EMC
MOTOR PHASES x3 +BAT (KL30)& GND
JTAG + NEXUS
EXT ERNAL MOTOR
POSITION
JTAG LABEL
JUMPERS
SENSOR
STAGES x2
Photo only for information.
Some elements may be different
KL15
FLEXRAY
SENT (TSU)
INDEX
EPS Generic Range
Eval boards
Available

20. October 7, 2014 I 20
Item Evaluation board
PCB control board
4-layers / High Tg 150°C
NiAu finishing
PCB Power board
IMS technology
3 shunts
Micro-controller
Panther – FSL - 144 LQFP
1,5 MB Flash / 180MHz ;
Power supply management
& Safety micro
Power SBC – FSL
MC33908
Gate Driver Unit Infineon TLE9180 Enhanced
Communication Flexray TJA1081A
Mosfets AUIRFS 8407 x 9
Phase switch control
Simple HW control / source to motor connection
Valeo concept for avalanche avoiding
Position sensor
Sleep Mode
2 modules available on the control board :
1xAMR (TLE5109) + 1 KMZ60 (R6) + 2 Melexis Hall sensor (R6)
No sleep mode
1 AMS integrated component
All in One (sensors & sleep mode)
EEPROM None (emulated)
EPS Generic Range
Evaluation boards / Key components
Available

21. October 7, 2014 I 21
EPS ECU development

22. October 7, 2014 I 22
3 undesired events:
Self steering – ASIL D
Blocking of the steering – ASIL D
Unexpected support – ASIL D
Safe state
open 3 phases in power module
Technical solution : safe switch phase by HW
open 1 phase in power module
Technical solution : open 1 phase by SW
Driver
request
ASIL D
Data
processing
ASIL D
3 phase
power
distribution
ASIL D
U
V
W
Electric Power Steering
Safety concept : Hazard analysis and risk assessment

23. October 7, 2014 I 23
Mosfet relay Mosfet HS Mosfet LS
Tj < 157°C Tj < 145°C Tj < 155°C
Time/Secs 20Secs/div
0 20 40 60 80 100 120 140 160 180 200
V
110
120
130
140
150
160
Time/Secs 20Secs/div
0 20 40 60 80 100 120 140 160 180 200
V
105
110
115
120
125
130
135
140
145
150
Time/Secs 20Secs/div
0 20 40 60 80 100 120 140 160 180 200
V
110
120
130
140
150
160
Electric Power Steering
Based on Valeo mission profile
Initial temperature of 105°C
Simulation of the maximum junction temperature during
the parking cycle

24. October 7, 2014 I 24
Electric Power Steering
Simulation of the DC Link capacitor lifetime
Equivalent life time with storage 125°C - 140°C : 1 607 hours
Based on
Valeo
mission
profile
Based on
Valeo
mission
profile

25. October 7, 2014 I 25
Medium Power
EMC filter simulation
Electric Power Steering
Common mode noise Differential mode noise

26. October 7, 2014 I 26
Electric Power Steering
Valeo sliding connector
Patented

27. October 7, 2014 I 27
SW development
Application Layer : composed of application specific software components (SWCs)
Runtime Environment (RTE) : provides communication services for SWCs
Basic Software (BSW) : manages memory, I/O, communication and system
services while abstracting ECU hardware
Layered software architecture
ESP GENERIC TEST SW available
Design of the complete SW (ASiL D &
Autosar compliant) based on a generic
platform (CMMi-2)

28. October 7, 2014 I 28
Next steps
Sign a NDA
Start discussions:
Which specifications?
What target price?
What potential businesses?

29. October 7, 2014 I 29