Global market review of starter motors and alternators forecasts to edition

Transcription

1 Global market review of starter motors and alternators forecasts to edition

2 Page i Global market review of starter motors and alternators forecasts to edition By Matthew Beecham April 2008 Published by Aroq Limited Seneca House Buntsford Park Road Bromsgrove Worcestershire B60 3DX United Kingdom Tel: +44 (0) Fax: +44 (0) Web: Registered in England no:

3 Page ii Single-user licence edition This report is provided for individual use only. If you would like to share this report with your colleagues, please order additional copies or sign up for a multi-user licence by contacting: Holly Nash Research manager, just-auto.com Tel: +44 (0) holly.nash@just-auto.com Copyright statement 2008 All content copyright Aroq Limited. All rights reserved. This publication, or any part of it, may not be copied, reproduced, stored in a retrieval system, or be transmitted in any form by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Aroq Limited. This report is the product of extensive research work. It is protected by copyright under the Copyright, Designs and Patents Act The authors of Aroq Limited s research reports are drawn from a wide range of professional and academic disciplines. The facts within this report are believed to be correct at the time of publication but cannot be guaranteed. All information within this study has been reasonably verified to the author s and publisher s ability, but neither accept responsibility for loss arising from decisions based on this report. Incredible ROI for your budget single and multi-user licences We understand the pressure your research budget is under and price our reports realistically. You won t find our reports with four, or even five-figure price tags, but you will find that they make some of the competition look expensive. Each title is available to you on a single-user basis, supplied on the strict understanding that each title is not to be copied or shared. Alternatively, titles can be shared within departments or entire corporations via a costeffective multi-user licence. Multi-user licences can also save you money by avoiding unnecessary order duplication. To further add value, all multi-user

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5 Page iv Contents Contents Single-user licence edition... ii Copyright statement... ii Incredible ROI for your budget single and multi-user licences... ii just-auto.com membership...iii Contents... iv List of figures... vi List of tables... vii Preface... 1 Research methodology... 1 Report coverage... 1 The author... 2 Chapter 1 The market... 3 Introduction... 3 Market trends... 3 Market players... 4 BBB Industries...4 Bosch... 4 Denso... 5 Q&A with Denso UK Aftermarket Sales... 5 Lucas Electrical Mitsubishi Electric Corp Motorcar Parts of America Inc Prestolite Electric Inc Remy International Valeo Emerging markets China India Poland Market shares Market forecasts Chapter 2 Technical review Defining the elements Recent innovations Starter motors and alternators Integrated starter-alternators Q&A with Valeo Q&A with ZF... 41

6 Page v Contents Chapter 3 Manufacturers Bosch Denso Lucas Electrical Mitsubishi Electric Motorcar Parts of America Inc Prestolite Electric Remy International Valeo... 56

7 Page vi List of figures List of figures Figure 1: Bosch Smart Electronic Start-Stop System... 5 Figure 2: Global market shares of OE alternators for passenger cars and light truck applications, 2007 (% of sales volume) Figure 3: Global market shares of OE starter motors for passenger cars and light truck applications, 2007 (% of sales volume) Figure 4: Gruau Microbus Figure 5: HX(F)95 starter series from Bosch... 45

8 Page vii List of tables List of tables Table 1: Market volume of OE alternators for passenger cars and light trucks, Europe, North America, Japan and China, (units 000s) Table 2: Market value of OE alternators for passenger cars and light trucks, Europe, North America, Japan and China, (EUR 000s) Table 3: Market volume of OE starter motors for passenger cars and light trucks, Europe, North America, Japan and China, (units 000s) Table 4: Market value of OE starter motors for passenger cars and light trucks, Europe, North America, Japan and China, (EUR 000s) Table 5: Market volume of alternators for passenger cars distributed through the OES and independent aftermarket, Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland, Italy, Netherlands, Portugal, Spain, Sweden and the UK, , (units 000s) Table 6: Market volume of alternators for commercial vehicles (less than 3.5 ton) distributed through the OES and independent aftermarket, Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland, Italy, Netherlands, Portugal, Spain, Sweden and the UK, (units 000s) Table 7: Market volume of starter motors for passenger cars distributed through the OES and independent aftermarket, Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland, Italy, Netherlands, Portugal, Spain, Sweden and the UK, , (units 000s) Table 8: Market volume of starter motors for commercial vehicles (less than 3.5 ton) distributed through the OES and independent aftermarket, Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland, Italy, Netherlands, Portugal, Spain, Sweden and the UK, (units 000s) Table 9: Denso Electric Systems net sales, (JPYm) Table 10: Denso Corp s starter and alternator production sites worldwide, Table 11: Valeo Electrical Systems Branch facilities worldwide, Table 12: Valeo Electrical Systems sales (EURm)... 58

9 Page 1 Preface Preface Research methodology This report is intended to provide an overview of automotive starter motors and alternators, providing top-level market volume and value forecasts from 2004 through to Our forecasts are not extrapolative but dependent on the underlying drivers of supply and demand. Our forecasts are largely based on interviews with the author s extensive international network of industry contacts. This allows us to consider and explain the meaning and implications of industry events, rather than offer simple description based on incomplete data. Our approach is divided into two distinct methodologies: qualitative interviews these are generally opinion-based, which aim to build knowledge about future automotive starter motor and alternator market trends and company strategies; and quantitative interviews typically fact-based, focused on establishing market values, shares, and volumes. Our research typically concentrates on applications for light vehicles which include all cars, light trucks and the various cross-over vehicle styles such as sports utility vehicles and people carriers. These vehicles collectively account for about xx% of the global vehicle build. Our market forecasts are set out by major light vehicle-producing region, i.e. Europe, Japan, China and North America. For the purposes of this report, Europe includes Austria, Belgium, Bulgaria, the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Switzerland, Sweden, Turkey and the UK. North America includes the US, Canada and Mexico. Report coverage In this, the fourth edition of this report, just-auto reviews the key market drivers for automotive starter motors and alternators, and updates the market analysis with exclusive Q&As with Denso, Valeo and ZF. Following our market

10 Page 2 Preface overview, just-auto s product fitment forecasts in Chapter 2 predict in some detail how the OE market for rotating electrics will evolve in Europe, Japan, North America and China from 2004 through This chapter includes our estimates and forecasts for the total (OES and independent) aftermarket for starter motors and alternators for passenger cars and light commercial vehicles (less than xxx ton) in Europe. Chapter 2 sets out a review of recent innovations in both conventional starter motors and alternators and integrated starter-alternators, while Chapter 3 provides brief profiles of the major manufacturers, namely Bosch, Denso, Lucas Electrical, Mitsubishi Electric, Motorcar Parts of America, Prestolite Electric, Remy International and Valeo. The author Matthew Beecham has more than 15 years experience of researching, writing and analysing market and technical trends in the global automotive components industry. Since 2000, he has served as an associate editor for just-auto. In addition to rotating electrics, he authors a range of global auto components market research reviews, including batteries, braking systems, coatings, clutches, cockpits, driver assistance systems, door modules, electric motors, engine cooling systems, exhaust systems, front-end modules, fuel injection, fuel tanks, glass, ignitions, interiors, lighting, mirrors, roof systems, shock absorbers, spark plugs, tyre pressure monitoring systems, tyres, wheels and wipers. Matthew s freelance assignments have included working for AT Kearney, McKinsey, Kuwait Institute for Scientific Research, Motorsport Industry Association, Motor Industry Research Association and the Economist Intelligence Unit. He has also written for magazines including Car Graphic (Japan), JAMA (Japan) and Automotive Engineer (UK). He was awarded a PhD in automotive technology transfer from Cranfield University.

11 Page 3 Chapter 1 The market Chapter 1 The market Introduction The increasing use of power-hungry options in modern passenger cars, such as heated seats and quick-defrost glass, electrically-powered brakes, water pumps, heated catalysts and advanced powertrains is placing unprecedented demands on automotive charging systems. The traditional Lundell-type alternator is unable to handle loads of this scale. New units emerging are capable of generating between xx% and xxx% of their rated amperage at idle speeds. In terms of design, the accent is on lightweight construction with higher outputs and better reliability than ever before. Manufacturers must also address environmental, noise and high underbonnet temperature concerns. Market trends The technology and specifications for the components used in starters and alternators (collectively known as rotating electrics) have become more advanced in response to the installation in vehicles of an increasing number of electrical components such as navigation systems, steering wheel-mounted electronic controls, keyless entry devices, heated rear windows and seats, high-powered stereo systems and DVD players. As a result of this increased electrical demand, rotating electrics require more advanced technology and higher-grade components. Consequently, per unit sales prices have increased. More specifically, the increasing complexity of passenger cars and light trucks and the number of different makes and models of these vehicles have resulted in a significant increase in the sheer number of different alternators and starters. While the latest starters and alternators provide for improved power generation capacity to support the above features, they are also smaller, lighter and quieter in order to improve fuel consumption, help reduce CO 2 and improve cabin comfort. Another major trend has been the gradual emergence of eco-friendly vehicles, which have systems that automatically switch off vehicle engines during idling, for instance at red traffic lights. According to various research studies, vehicles are at a standstill for one-third of the time while in urban areas. Stop-start

12 Page 30 Chapter 2 Technical review Chapter 2 Technical review Defining the elements The starter converts electricity into mechanical energy while the alternator turns mechanical energy into alternating-current electricity. In other words, it provides electricity for the vehicle and keeps the battery charged. According to Bosch, the starter consists of the following assemblies: electric motor, pinionengaging system, roller-type overrunning clutch, pinion and reduction gear set. During the start, the starter pinion engages with the ring gear by means of a solenoid switch. The starter is either coupled to the starter pinion directly or by means of a reduction gear set, which reduces the rotational speed of the DC motor. The starter pinion drives the internal combustion engine via the engine flywheel ring gear until the engine can run at sustained operation, says Bosch. Alternator output is directly related to frame size, or diameter. According to Bosch, the alternator must furnish the vehicle electrical system with a sufficient supply of current under all operating conditions in order to ensure that the state of charge in the battery is always maintained at an adequate level. The aim is to achieve balanced charging, i.e. the characteristics for performance and speed-frequency response must be selected to ensure that the amount of current generated by the alternator under actual operating conditions is at least equal to the consumption of all electrical equipment within the same period, says Bosch. The alternator actually produces alternating current. The vehicle electrical system, on the other hand, requires direct current to recharge the battery and operate the electrical equipment. It is this direct current that must ultimately be supplied to the electrical system. A bridge rectifier integrated in the alternator converts the three-phase alternating current. Integrated starter-alternator systems aim to balance out irregularities in the running engine and in the drivetrain, providing more comfort. Clever electronics do the trick here. They help to control the starter-alternator operating state, depending on the load and battery charge status. Features such as the stop-start 1 function (which results in better fuel economy) will be a 1 Stop-start systems switch off the internal combustion engine when the vehicle is at a standstill such as in traffic jams or at red traffic lights. This helps effectively reduce fuel consumption and CO2 emissions, particularly in urban traffic.

13 Page 44 Chapter 3 Manufacturers Chapter 3 Manufacturers Bosch Germany s Bosch Group is organised into three corporate divisions: Automotive Technology; Industrial Technology; and Consumer Goods and Building Technology. On 1 November 2006, Bosch s Automotive Technology division was reorganised into ten business divisions, namely: Gasoline Systems; Diesel Systems; Chassis Systems Brakes; Chassis Systems Control; Electrical Drives; Starter Motors and Generators; Car Multimedia; Automotive Electronics; Automotive Aftermarket; and Steering Systems. The main organisational change involved dividing its former Energy and Body Systems division into the Electrical Drives division and the Starter Motors and Generators division in order to sharpen their focus on the needs of these two markets. At the time of the reorganisation, Bosch reported that both divisions operate in exceptionally difficult competitive environments. Bosch s Starter Motors and Generators division designs and manufactures starter motors and alternators in a number of rating classes. These are suitable for passenger cars and commercial vehicles for diesel and gasoline engines. The division employs xxxxxx people in xx locations worldwide. In addition to starters and alternators, the division provides technical solutions for commercial vehicles, software and electronics, components for engine thermal management, climate control components, seating comfort systems and actuator technology for various assemblies, mechatronics for side doors, roof, windscreen and rear window cleaning systems. Bosch s alternator product range includes LI-L long life alternator, T1-MP highpower units for buses, LI-E, LI-F, and its new LI-X generation.