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October 7, 2014 I 1
Nexteer / VALEO
Meeting in Troy
October 7, 2014
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 €
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
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
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
October 7, 2014 I 6
2013 OEM Sales
2.7B€
Powertrain : A diversified Customer Base
French
Asian
Other
American German
2013 figures
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
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)
October 7, 2014 I 9
Medium Power Electronics
Product overview
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
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
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
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
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
October 7, 2014 I 15
EPS GENERIC
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
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
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
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
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
October 7, 2014 I 21
EPS ECU development
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
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
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
October 7, 2014 I 25
Medium Power
EMC filter simulation
Electric Power Steering
Common mode noise Differential mode noise
October 7, 2014 I 26
Electric Power Steering
Valeo sliding connector
Patented
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)
October 7, 2014 I 28
Next steps
Sign a NDA
Start discussions:
Which specifications?
What target price?
What potential businesses?
October 7, 2014 I 29

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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?