EUREKA PROJECT > 3734 I-STARS
FRANCE
INTEGRATED STARTER ALTERNATOR REVERSIBLE SYSTEM
DEVELOPMENT OF A NEW TECHNOLOGY ALLOWING A VERY HIGH LEVEL OF INTEGRATION APPLIED TO THE AUTOMOTIVE INDUSTRY TO EXTEND THE 'STOP-START' FUNCTIONALITY FOR HIGH VOLUMES AT LOW COST.
Status > FINISHED - 05-Apr-2010 Technological Area Market Area Start Date > 01-Apr-2006 Duration > 48 Months Participating countries > FRANCE, BELGIUM, GERMANY | Main contactVALEO ELECTRICAL SYSTEMS
MR. ANTOINE DE MONTS > R & D / PROJECTS MANAGER Organisation type > Large company |
Project Description
VALEO has developed the first generation of 'Stop-Start' systems (VALEO StARS: Starter Alternator Reversible System), today in serial production with CITROEN. StARS performs a comfortable 'Stop-Start' function in complete transparency for the driver: the belt driven starter-alternator system shuts down the engine during idle phases and restarts the engine quickly and silently on request. This results in no fuel consumption, gas emission, vibration or noise at standstill. Furthermore, StARS allows for a high efficiency alternator mode featuring synchronous rectifying and allowing for a better energy balance of the vehicle. Based on this initial experience, VALEO wants to launch the second generation of 'Stop-Start' systems dedicated to big production volumes. Tomorrow's hybrid solutions have to be as minimally intrusive as possible on standard mass produced powertrains. This low intrusiveness calls for a high level of integration between the electrical machine assisting the internal combustion engine and its associated power and control electronics. This high level of integration imposes harsh thermo-mechanical constraints on the whole system, pushing away standard electronic assembly technologies as well as robust electronics developed for railway and industrial applications which do not correspond to automotive industrial requirements in terms of flexibility, yield and cost. The main objective of the project is to integrate all the power electronics and a part of the control electronics at the back of the machine. (Today on the first generation of system, the electronics are located in a separate box). Therefore, specific electronic components have to be developed to meet this challenge: AMIs for the ASIC (Application Specific Integrated Circuits) design. The research and development is performed in Creteil (South of Paris) while the manufacturing plant is located in Etaples sur mer (North of France). Car manufacturers will test I-STARS on vehicles. Keywords: automotive hybrid.
Technological Development Envisaged
The main deliverables are split into work packages (WP): WP1: SYSTEM SPECIFICATIONS (VALEO) VALEO will write the system specifications with car manufacturers. Driving and controlling the I-STARS system requires 2 new ASIC circuits plus discrete power MOSFET (Metal Oxide Silicon Field Effect Transistor) transistors. VALEO will build the specifications of the power electronics and the electronic control (ASIC driver and ASIC controller). VALEO will design, prototype and test the dedicated power MOSFET transistors. WP2: POWER ELECTRONIC MODULE (VALEO) VALEO develops the power module and the required silicon for the start-stop system with the support of the 'Valeo Center of Electronic Expertise". AMIS will design, prototype and test the 2 new ASIC circuits: the ASIC DRIVER and the ASIC CONTROLLER. Both circuits operate in a very harsh environment, i.e. electrical disturbances, high temperatures and mechanical shocks. High reliability in a harsh environment offers tough challenges for the design, processing and assembly of these ASIC circuits. WP3: ASIC DRIVER (VALEO-AMIS) WP4: ASIC CONTROLLER (VALEO-AMIS) WP 3-4 Description see AMIs contribution and expertise) WP5: ELECTRICAL ARCHITECTURE (VALEO) Car manufacturers with VALEO will design and test the right electrical architecture to drive I-STARS on cars. WP6: MACHINE PROTOTYPE (VALEO) VALEO will design, prototype and test the integrated electronics on the electrical machine. DV: Device Validation is included in WP2-3-4-6 PV: Process Validation is included in WP7 WP7: EVALUATION AND VALIDATION (VALEO-ALL) Validation of the technology (Device and Process Validation) WP8: GENERAL PROJECT MANAGEMENT (VALEO-ALL) This project is managed by VALEO as a so-called P2 project (Generic product development). WP 2-3-4-6 can be split into two sub WPs (first prototypes and second prototypes).
Main contactVALEO ELECTRICAL SYSTEMS
MR. ANTOINE DE MONTS > R & D / PROJECTS MANAGER Organisation type > Large company |
Contribution to project
WP1: Leader WP2: Leader WP3: Contributor WP4: Contributor WP5: Contributor WP6: Leader WP7: Leader WP8: Leader
Expertise
?The organisation is an independent global industrial group fully focused on the design, production and sale of components, integrated systems and modules for cars and trucks, in both the OEM (Original Equipment Manufacturers) and aftermarket segments. The core business of VALEO ELECTRICAL SYSTEMS (VES) relates to alternators and starter motors. (Number 2 for alternators and number 3 for starter motors worldwide in 2005). Its core expertise is electrical machine design for the automotive market, including electronic control systems. VES has successfully developed the stop-start concept and intends to develop it through high volume mass production. The first generation of StARS has equipped the CITROEN C3 Stop & Start since November 2004 and C2 Stop & Start since January 2006. PEUGEOT announced in its press release that the 207 will also feature the Stop & Start functionality in Gasoline and Diesel engines, with various engine displacements and types of gearboxes. VALEO's roadmap is based on a smooth and continuous approach towards hybridisation of the powertrain, which involves firstly understanding each functionality step by step, then developing applications corresponding to clearly identified needs. Thus, VALEO is developing a range of solutions based on belt driven starter alternator reversible systems as assistance to the engine. This results in a cost and functional efficient solution for Stop-Start - which represents the cornerstone for hybridisation of the powertrain - and which also allows for adding other functionalities such as Regenerative Braking and Torque Assistance at a minimal cost.
Main contactON Semiconductor Belgium BVBA MR. EDGARD LAES > MANAGER R & D PROGRAMMES Organisation type > Large company |
Contribution to project
1. ASIC DRIVER (WP3) LEADER The ASIC driver is connected, via external power transistors, to one branch of the alternator. An AMIS smart power technology that can handle 100 Volts will be selected for the design and production of this ASIC. The ASIC will be partitioned for high robustness and minimal influence from ground shift and other disturbances. New analogue and power building blocks will be designed. Robustness will be assessed during the design by top-level simulation. Several design iterations will be required to achieve all the targets. 2. ASIC CONTROLLER (WP4) LEADER The Controller ASIC monitors and controls the overall system. It contains a micro-controller, analogue sensor interfaces for accurate monitoring and several regulated power supplies. The controller is connected to the car network for communication to the car electronic system. The R & D work involves similar steps as for the ASIC Driver: partitioning, design of the new building blocks, top-level simulation and prototyping. A test programme will be generated to fully characterise the prototypes. Circuits are then mounted in a complete system to assess performances in harsh environments. Based on the outcome of the characterisation, design updates might be needed. AMIs will also contribute to WP 1 & 7.
Expertise
The organisation (AMIS) is a world leader in the design and manufacturing of application-specific integrated circuits (ASICs) with headquarters in Pocatello (Idaho, U.S.) and Oudenaarde (BELGIUM). AMIS employs almost 1,000 people in Europe with design centres in Vilvoorde, Oudenaarde (BELGIUM), Brno (CZECH REPUBLIC), Marin (SWITZERLAND), Sofia (BULGARIA) and Penningen (NETHERLANDS). AMIS BELGIUM designs, manufacturers and sells standard products for specific applications, ASSPs (Application Specific Standard Products), and custom made ASICs for the telecom, automotive, peripherals and industrial sectors. A key strength is the mixed-signal circuits, often combining CMOS (Complementary Metal-Oxide Silicon) with analogue, NVM (Non-Volatile Memory) and high voltage devices. A large R & D effort is dedicated to mixed-signal and high-voltage devices and process technology, innovative design and test techniques and new circuit concepts. Engineers from AMIS BELGIUM have co-operated with many European partners in the framework of the IST (Information Society Technologies) and MEDEA projects. AMIS has 2 integrated circuit fabrication lines in Oudenaarde, BELGIUM, which are primarily dedicated to smart power processes. The process capabilities range from 20V to 100V. The I3T family is a state-of-the art smart power process: it is based on CMOS 0.35 micrometers allowing dense logic, extensive analogue signal processing and the integration of flash memory and DMOS based switches and drivers. This process technology and the related design expertise are optimal for designing and manufacturing the control circuit for this project.