II Valeo unveils its major innovations at the Automotive Engineering Exposition

Transcription

1 1 CONTENTS I Innovation, Valeo's growth driver - Investing to invent the automobiles of tomorrow - Valeo Innovation Challenge 2 2 II Valeo unveils its major innovations at the Automotive Engineering Exposition - Laser Scanner SCALA - Sightstream TM Camera Monitoring System Smart wipers for the autonomous car s cameras 6 - Electric Supercharger 6 - EG Efficiency Alternator -12V Belt Starter Generator istars - Hybrid4all - High efficiency on-board charger for electric and hybrid vehicles - Valeo solutions for PHEV: Inverter - Torque Converter with LTD Pendulum - Water Cooled Charge Air Cooler - EGR Cooler Active Air Battery Conditioner Appendix - About Valeo 12 - About Valeo in Japan 13

2 2 I Innovation, Valeo's growth driver Investing to invent the automobiles of tomorrow Valeo's growth strategy is based on international expansion, particularly in Asia, and on innovation. The Group's goal is to help invent automobiles of tomorrow, which will be safer, smarter, more fuel efficient and more enjoyable to drive. Valeo has set the ambitious target of generating more than 20 billion in revenue by 2020, compared with 12.7 billion in To get there, the Group is counting both on geographical expansion, especially in Asia, and on the ability to invent the car of the future through innovation. The share of automotive value added by suppliers is growing on a regular basis. It rose from 70% to 80% between 2000 and 2015, which is expanding the scope of products as well Valeo invests more than 10% of original equipment sales into R&D, with 10,400 researchers working in some 50 centers covering all four of the Group s business groups. The figures speak for themselves: Valeo filed over 1,100 patents in 2014, 40% more than the previous year, and took 17.5 billion in orders, up 18% year on year. A full 35% of those orders were for innovative products brought to market within the previous three years. Valeo Innovation Challenge The Valeo Innovation Challenge invites students from around the world to play an active role in automobile innovation by designing the product or system that will create smarter, more intuitive cars by With the Valeo Innovation Challenge, Valeo is demonstrating once again that innovation and R&D are top priorities for the Group. Indeed, innovation guides the teams who are working each day to invent the car of tomorrow. Valeo named the 20 teams shortlisted by its 80 experts to compete in the second round of the Group's Global Innovation Challenge on April 1st. The participating teams come from all over the world and represent a total of 12 different countries: China, Egypt, Germany, India, Malaysia, Poland, Russia, Spain, Turkey, the United Kingdom, the United States and Uzbekistan. The shortlisted teams now have until July 17, 2015 to develop a working prototype of their project using the 5,000 in funding allocated to each of them by Valeo. Six finalist teams will then be selected to present their project to the jury during the Frankfurt Motor Show (IAA 2015). The jury will be chaired by Jacques Aschenbroich, Valeo Chief Executive Officer, and

3 3 will comprise members of the Group s senior management team, as well as eminent figures from the worlds of science and design. The winning team will take home 100,000 in prize money and the second and third-place teams will receive 10,000 each. For more information:

4 4 II Valeo unveils its major innovations at the Automotive Engineering Exposition Valeo is presenting its major innovations which contribute the CO 2 emission reduction and the intuitive driving. As a technology company, Valeo offers systems and innovative technologies to: Reduce CO 2 emissions and improve fuel efficiency. Make cars smart, connected and fun to drive, in a concept known as intuitive driving. Although awareness about such issues as global warming or the need to reduce fuel consumption differs from one part of the planet to another, there is no getting around the fact that the transport sector accounts for a quarter of global CO 2 emissions and needs to find affordable solutions to reduce its oil consumption. This explains why increasingly ambitious standards are being put into effect all around the world. Each carmaker s new vehicle fleet will have to comply with a maximum average CO 2 target of 95g/km in Europe by 2021 and 105 g/km in Japan by Achieving technological advances to reduce CO 2 and polluting emissions is one of the two main paths in Valeo's innovation strategy. The Group s main technological developments relating to improvements in fuel consumption, include: internal combustion engine efficiency, electrifying powertrains, making a vehicle's different functions more energy efficient and reducing component weight. Valeo s Hybrid4All system, for example, will generate fuel savings of up to 15% at half the cost of current hybrid solutions. Valeo also offers comprehensive solutions to optimize a vehicle's thermal management, increasing internal combustion engine efficiency while reducing the energy needed for passenger cabin comfort. One example of this is the water-cooled charge air cooler, which paves the way for more compact and less polluting turbocharged engines. Reducing fuel consumption is not the only way to shrink a vehicle's total environmental footprint, however. Valeo is also careful to integrate eco-design in its R&D. In addition to fuel efficiency, motorists are looking for cars that are connected, autonomous, easy to use and fun to drive. Valeo is responding to these expectations with its intuitive driving concept, which is designed to facilitate maneuvering in city driving, assist motorists in different driving situations and make it easier for vehicles to interact with other drivers and the surrounding environment. Valeo s driving assistance systems offer a range of smart technologies that improve driving safety and comfort. Increasingly sophisticated functionalities are added each year to enhance safety and comfort in city driving. The Laser Scanner SCALA, which scans the forward surrounding of the vehicle, and detects vehicles and static obstacles, and Sightstream smart mirror, which replaces the rearview mirrors with a camera, are just two examples of what motorists can expect in the future.

5 5 Laser Scanner SCALA Valeo SCALA laser scanner scans the forward surrounding of the vehicle, and detects vehicles, motorbikes, pedestrians and static environment like trees, parked vehicles and guard rails. Based on the detected obstacles an environment map is created with relevant data for all classified objects. It serves to enhance active safety, like emergency braking for vehicles and pedestrians, evasion maneuver, and provides essential information for automated driving features, like automated valet parking or a traffic jam pilot. The detection of obstacles by the laser scanner works at any time of night and day, and it functions at high speeds on the expressway as well as low speeds when parking. The laser scanner will be served as key detection system for an automatic emergency braking system, whose assessment will be included in the rating scheme of Euro NCAP from 2014 onwards. The laser scanner technology complements Valeo s existing range of radar, ultrasonic, infrared and vision sensor systems. Valeo, who is already market leader in driving assistance systems, will be able to promote innovative active safety features and automated driving. One example of the laser scanner application in the future is the automated driving prototype, Cruise4U TM, which was demonstrated at this year's CES in Las Vegas, U.S.A. At CES, Valeo conducted its demonstration in real traffic: when engaged, drivers decide if they want to manually control the vehicle or let Cruise4U TM take control of the steering, accelerating and braking. Laser scanning technology detects moving or stationary obstacles to avoid collisions. Sightstream TM Camera Monitoring System Valeo is committed to offering high technology solutions with improved ergonomics that make driving safer, easier and more natural. As part of this commitment, Valeo teams have developed Sightstream TM, a new system that replaces conventional rearview mirrors with cameras. Cameras are installed where the interior rearview mirror and exterior side mirrors are usually mounted. This considerably improves vehicle aerodynamics and helps save fuel. What used to be seen outside the car is now viewed on the inside, improving the driver s side vision by making the images clearer and easier to see, whatever the weather. Sightstream TM Camera Monitoring System offers new styling potential, as the rear and side view mirrors are replaced by cameras. Removing the central rearview mirror makes it possible to redefine the rear of the vehicle, which can be narrowed. The removal of the side view mirrors has three benefits: first, it reduces vehicle drag and therefore CO 2 emissions by up to 1.3 grams per kilometer, second, it decreases the noise generated by the mirrors, and last, it can eliminate blind spots caused by the side view mirrors.

6 6 The Sightstream TM system can embed driving assistance system features such as blind spot detection; assist with door opening by detecting vehicles, motorbikes or bicycles; and help the driver during lane changing or overtaking by providing information on the Sightstream TM display. Valeo is following the procedures undertaken by the European Commission as part of an ISO standardization program. EU legislation will authorize the replacement of side mirrors by cameras in Smart wipers for the automated car's cameras Valeo has invented a customized wiper that can clean the entire windshield while focusing especially on the area in front of the cameras that allow vehicles to operate autonomously. Mini digital cameras already play a part in such driver assistance systems as anti-glare headlamps, pedestrian detection and emergency braking. In the next few years, these cameras will assist drivers in all situations by providing a broader and more precise field of vision than that available to the human eye. With the new wiper, the camera's vision will be clear at all times. The development of the automated driving car requires uncompromised camera operation and visibility. The AquaBlade system with camera cleaning is the optimal solution for perfect camera visibility. For more than 30 years, Valeo has revolutionized windshield wiper and cleaning systems. After the heated wiper with integrated cleaning, Valeo has invented AquaBlade with camera cleaning. Based on AquaBlade wiper technology, camera cleaning guarantees clear, accurate and reliable vision for the automated car. Thanks to the precise stream of cleaning fluid and the wiper blades adjustable positioning, AquaBlade technology helps reduce both cleaning fluid use and tank size, thereby also contributing to an overall reduction in vehicle weight. Electric Supercharger In response to stringent emissions regulations, downsized engines are one key lever for carmakers to reduce CO 2 emissions and fuel consumption. To maintain engine performance, Turbocharged Direct Injection technology, driven by exhaust gases, can be used, increasing global performance but also, resulting in a longer response time called turbo lag. Valeo is the first automotive supplier to offer a range of electric superchargers with immediate response of the engine. Unlike a turbocharger, an electric supercharger functions independently of the air loop. It is indeed driven by an electrical motor integrating switched reluctance technology that responds instantly (250 milliseconds). As a result, it delivers torque on demand, thereby eliminating turbo lag.

7 7 The instantaneous response enhances fun-to-drive and enables carmakers to optimize ingear acceleration without impacting fuel efficiency. Used with a 12-volt electrical architecture, it can reduce fuel consumption by 10%. When coupled with a Valeo energy recovery system, electric superchargers can be used to create a cost-competitive hybrid solution that delivers fuel savings of 15% to 20% in standard European driving cycles. Requiring little change to the powertrain architecture, the system can be integrated rapidly and at a lower cost on new and existing vehicles. A conclusive demonstration of the electric supercharger system was carried out on 1 to 2.4- liter naturally aspirated engines as well as on 1 to 4-liter turbocharged gasoline and diesel engines. Valeo has developed an electric supercharger for conventional 12 and 48 volts future architectures of, with the goal of significantly improving power and efficiency. In the Automotive Engineering Exposition 2015, Valeo present for the first time, its 48V Water-Cooled application. EG Efficiency Alternator Valeo presents for the first time its EG Efficiency Alternator which features synchronous rectifying based on MOSFET (Metal Oxide Semiconductor Field Effect Transistors) instead of diodes. Thanks to their micro-electronic structure, MOSFET s are able to almost eliminate the voltage drop during current rectifying. This product allows to increase by 10 percent the alternator s efficiency. Valeo has won a 2015 Automotive News PACE (Premier Automotive Suppliers' Contribution To Excellence) award for its EG Efficiency Alternator. 12V Belt Starter Generator i-stars In city driving conditions, vehicles are stationary for about 35% of the time, while the engine idles to no purpose. Stop-Start function switches the engine off automatically when the vehicle is at standstill, at a red light for example, and starts it automatically and rapidly as soon as the driver asks for power. Stop-Start became a significant stake for CO2 emissions reduction, allowing 6%* consumption reduction, and up to 15%* in congested urban traffic. Starter-alternator i-stars replaces the alternator and can easily be fitted on any engine strategy specified by the automaker. It works on both manual and automatic transmissions. In alternator mode, the power electronics improve the system's electrical efficiency making it also the most efficient alternator on the market. The control and power electronics integration in the unit makes it easier to install in the engine compartment and reduces the system cost. i-stars shuts off the vehicle s engine when vehicle speed drops below 8 km/h for automated transmissions, and below 20 km/h for manual transmissions, but most of all, allows an immediate (400 msec) and silent engine start via the belt drive that permanently links the system to the crankshaft, without any vibration even if the driver unexpectedly changes his or her mind while stopping.

8 8 Recently, Valeo also developed a more powerful i-stars system for Nissan: i-stars Boost combined with an additional battery that ensures braking recovery and delivers electronic assistance to the engine. This hybrid functionality generating fuel savings and further CO2 emissions reductions (+3%) enabled Nissan to obtain Hybrid vehicle qualification according to Japanese regulation. Over 50 vehicle models will be fitted with Valeo Stop-Start systems by Hybrid4all Valeo's Hybrid4all is the result of its search for a better trade-off between price and environment, in order to make hybrid technology affordable for everyone. Valeo's Hybrid4all is appropriate for vehicles in segments A, B and C. Hybrid4all can generate fuel reductions of over 15% and can halve the cost per gram of CO 2 saved. Three factors contributed to this performance: Simplification: the system has been optimized, using a single electric motor and electronic unit. The size of the system's components has been optimally reduced to the "strict minimum". Standardization: the use of standardized components enabling a reduction in the overall cost of the system. Integration: integration by the automakers has been simplified, requiring no changes to the transmission, since the electric motor replaces the starter. Hybrid4all has the following functions: Enriched stop-start, with the possibility of cutting the combustion engine at higher speed, faster starting, etc High-efficiency power generation Regenerative deceleration and braking Torque assistance, helping the combustion engine to downsize and downspeed Start-up in electric mode The ability to use electric mode for low-speed maneuvers, limited acceleration or at stable speeds up to 70 km/h Valeo's Hybrid4all is compatible with diesel and gasoline engines. This system ensures manufacturers compliance with future EU CO 2 emissions norms to the year High efficiency on-board charger for electric and hybrid vehicles Valeo is presenting a 3.5kW on-board charger with an 8 hour recharge time and minimal energy loss. Valeo s on-board charger offers optimum charging time for electric or hybrid vehicles. Thanks to its efficient technology, the charger features industry leading 96% power conversion efficiency, which means virtually no energy loss.

9 9 As a specific regulation is currently being defined, it is already certain that carmakers will have to provide information on charger power conversion efficiency, just like they do for CO 2 emissions. Labeling will become mandatory in the next few years. The simplest design possible was used for the charger, which is suited to different battery technologies. Thanks to its compact size and shape, which drastically reduced its volume, the charger can be mounted in any available space in an EV or plug-in hybrid. This reduced bulk also means less weight a key issue for electric vehicles. Valeo s high efficiency onboard charger is currently being produced for the Volvo V60H. As part of the Group CO 2 strategy and to be the supplier of choice for carmakers, Valeo develops in-house a large high voltage power electronics portfolio for Hybrid, Plug-in to full electric vehicles. In addition to the battery charger, Valeo develops stand-alone inverters, and has also designed a charger/inverter that combines the 2 functions into one device. Valeo s product portfolio also comprises the DC/DC converter. Valeo solutions for PHEV: Inverter As part of its strategy for CO 2 emissions reduction, Valeo develops a comprehensive range of products for EVs and PHEVs including power electronics such as onboard chargers, DC/DC converters and inverters. The inverter converts direct current (DC) from the battery into the alternating current (AC) required by the electric motor to turn the wheels. Depending on the application power needs, Valeo offers a large range of inverter, from 30 to 320 kw. Thanks to their high efficiency, Valeo s inverters help to reduce the power consumption of the electric powertrain and allows by the same way to improve the vehicle range. Valeo solutions are compact and could easily be mounted on most electric architectures (up to 40 kw/liter) Valeo also develops solutions combining functions such as Inverter/DCDC or charger/inverter. Torque Converter with LTD Pendulum The pendulums generate an opposite phase vibration against the one from the engine and contributes to reduce significantly the noise and the vibration of the entire vehicle. Applying the patented technology, Valeo Pendulum improved about 15% the NVH efficiency versus conventional products. This technology can be applied to all the drive-train dampers. In

10 10 combination with Valeo s long travel damper technology, it ensures the lower lock-up speed below 1000 rpm. Water Cooled Charge Air Cooler The Water Cooled Charge Air Cooler is a compact brazed aluminum heat exchanger cooled by water which allows fuel economy and emissions reductions compared to a conventional air-air cooler. It also improves the vehicle s acceleration behavior and creates more front packaging space. Most diesels and an increasing number of gasoline engines, are turbocharged and therefore equipped with a CAC. Turbocharging increases power for the same cubic displacement, or produces the same level of power with reduced fuel consumption and pollutant emissions. The intake air entering turbocharged engines is traditionally cooled by an air-air heat exchanger located at the front of the vehicle. Valeo has developed a different technology to improve performance: an air-to-water heat exchanger in which the intake air is cooled by a cold water flow. The main benefit is more efficient cooling as water has four times the heat transfer capacity of air. Furthermore, the intake air circuit is shorter, which reduces the engine s acceleration lag time. It can be located in the engine s intake manifold, eliminating the need for hoses between the engine and the front end of the vehicle. The reduced volume between the turbo-charger outlet and the intake valves reduces response time when accelerating. The time taken to reach maximum turbocharging pressure at the engine intake is cut by about 250 milliseconds at 1,500 rpm, or ~14 percent. EGR Cooler As in Water Cooled Charge Air Cooler (WCAC) technology, the Valeo s Exhaust Gas Recirculation module (EGR) or EGR system is another parallel technology that lends a hand in reducing emissions and improving fuel economy. The EGR loop takes a percentage of the exhaust gases at the cylinder head outlet and re-injects it back into the engine s air intake. The main benefits are fuel efficiency and NOx emission reduction. Emissions are treated at the source rather than by post-treating the exhaust-gases. The result is a cleaner combustion process. EGR module includes an electric valve to control the gas-flow and an EGR cooler which is a coolant to air heat exchanger. Depending on customer requirements the exchanger is made of stainless or ferretic stainless steel able to withstand the corrosive and high temperature exhaust gas environment. Coupled with optimized air and coolant pressure drops the design specifics of tube/fin arrangement limit the fouling of the heat exchanger.

11 11 The electric EGR valve assembly encompasses an electric motor, a cam / gearing system, a piston-valve, and a position sensor. The valve can be fully opened or closed in just 100 or 75 milliseconds respectively. A distinctive feature is the progressive cam-driven control device that converts the rotary movement of the e-motor into a controlled downward travel of the valve. The cams can be used to address several priorities according to valve travel. Valeo has opted for an outward-opening valve for greater dependability since the high exhaust gas pressure generated by a turbocharger applies a force that tends to close the valve. The aerodynamics of the valve head, clearance area, and small diameter of the shaft contribute to a low pressure loss in the gas recycling circuit. This property is especially important when idling and at low loads. A Hall-effect sensor precisely measures the position of the valve. This precise recirculation rate reduces the flow tolerances and, importantly, enables the engine to meet the more and more demanding regulations (e.g. Euro V). Active Air Battery Conditioner The Active Air Battery Conditioner integrates a refrigerant cooled heat exchanger (evaporator) and a high voltage air heater. It controls the high volt battery temperature during quick charging and normal use of EV and PHEV thanks to high cooling and heating power. The Active Air Battery Conditioner works with recycled air and can therefore be put under floor in a hermetic battery pack. Advantages of the Valeo system are good battery temperature homogeneity and very low noise level. Battery temperature control stabilizes battery performance and increases the life span of the battery. Good battery thermal management enables range optimization of EVs.

12 12 Appendix About Valeo Valeo is a major player in the global automotive industry and ranks among the world s top automotive suppliers. As a technology company, Valeo is fully focused on the design, production and sale of components, integrated systems and modules for the car and truck industry in both the original equipment and replacement segments. With its intuitive driving concept, Valeo develops innovative technologies that provide optimal safety, enhanced driving comfort and greater energy efficiency. The Group offers solutions that reduce the consumption of internal combustion, hybrid and electric vehicles, as well as the weight and energy use of components. Major customers by alphabetical order include: BMW, BYD Auto, Chery, DAF, Daihatsu, Daimler, Fiat/Chrysler, FAW, Ford Motor Company, Geely/Volvo Cars, General Motors, Great all, Honda, Hyundai/ ia, AC, Mazda, Mitsubishi, PSA Peugeot-Citro n, Renault-Nissan, SAIC, Subaru, Suzuki, Tata Motors/Jaguar/Land Rover, Toyota, Volkswagen Group/Porsche/Scania/MAN and Volvo Trucks. Key figures billion in 2014 sales, up 9% compared with More than 10.4% of OEM sales devoted to R&D, or more than 1.1 billion in ,100 patents filed in 2014, 41% more than in ,200 employees - Operations in 29 countries - 15 distribution platforms - 16 research centers - 34 development centers production sites

13 13 About Valeo in Japan Valeo marked the first step in Japan by establishing a Japanese branch in December Valeo Group in Japan comprises two entities, Valeo Japan and Valeo Unisia Transmissions (a joint-venture with Hitachi Automotive System) with 9 production sites and 3 R&D centers. Valeo in Japan employs 2,800 people. In addition, Valeo has a global alliance with Ichikoh Industries for lighting business and a partnership with PIAA for sales in Japanese after market..