PEL Power Steering

Nexteer

March 31th, 2016

 High Power In production

Medium Power Product Line On-going development

Advanced Project
Portfolio Potential

12V 24V 48V >100V

HEPS
EPS
ECU
TCU
E-Clutch
E-Brake
DCDC xV-12V
EG
i-StARS
i-BSG
GMG, CMG, DMG
Range Extender (SW)
ESC
EDC

More than 15 years of experience in 12V EPS & HEPS products

Confidential March 31th, 2016 I 2

Property of Valeo. Duplication prohibited
 Valeo Power Module IML : Insulated Molded Leadframe
DBC : Direct Bonded Copper
IMS : Insulated Metal
Substrate PCB : Printed Circuit
Board
Power density SMT : Surface Mounted
Technology
Compactness
i-StARS i-BSG

EPS
IML
EG

DBC DIE LASER

SOLDERING
HEPS

IMS

Engine ECU
PCB WIRE
BONDING
SMT
OVEN REFLOW Thermal
Dissipation

Core competency in power module (Design & Manufacturing)

FR4, IMS or DBC in function of the rated power and the
compactness
Confidential March 31th, 2016 I 3
Property of Valeo. Duplication prohibited
 Power Steering
Portfolio
Electric Power Steering Hydro Electric Power Steering

ASiL D

ASiL B

Leader on the premium EPS in Europe
(Daimler, BMW, AUDI)
3 M units / year
Confidential
Property of Valeo. Duplication prohibited
More than 15 millions product on the
market
(PSA, Renault, Dacia)
1,5 M units / year
March 31th, 2016 I 4
 Power Steering
Market
Rack
KW 48V EPS

48V SHP

Potential new business

1,5 for 48V network

Rack
EPS

1
HEPS
Column
EPS
HPS : Hydraulic Power Steering
HEPS : Hydro-Electric Power Steering
EPS : Electric Power Steering
0,5
SHP : Steering High Power
12V system area

A/B C D/E SMALL TRUCK

1 2 3 4 5 Tons

Fast growth for 12V EPS

Confidential
No request for 48V EPS in Europe
Property of Valeo. Duplication prohibited
March 31th, 2016 I 5
 Power Steering
EPS Road Map
Quantity
200W
Standalone
EPS
City cars Column
& standalone
Subcompact cars EPS
Rack + Column
Pinion
Compact cars
600W
Rack & Pinion
E-BKV
Mid-size cars

Upper mid-size cars

EPS
Premium Daimler
BMW
Upper class
1kW Rack
Luxury class MLB Audi

Core competency in electronic

Off-road vehicles (Mechatronics, HW & SW control,
Power Module)
Performance Can deliver complete power pack

Confidential March 31th, 2016 I 6

Property of Valeo. Duplication prohibited
 Power Steering
Mechatronics 1/2 : Medium & Low Power

160 A peak 140 A peak 130 A 130 A peak

peak

Long

54mm
101.5mm
125.3mm
103mm

124mm

117mm
Short
96.3mm

117mm

Ø93mm Ø93mm

- Discrete control board on FR4 - Discrete control board on FR4 - Discrete control board on FR4
- DBC power module - IMS power board - FR4 power board
- Electronic on chassis - Electronic on chassis - Chassis removal
- ECU assembly at Valeo - ECU assembly at Valeo - ECU assembly at OEM

Discrete technologies are used until their maximum operating area

Mechanical parts are optimized thanks to a better process integration with the
motor
Confidential March 31th, 2016 I 7
Property of Valeo. Duplication prohibited
 Power Steering
Mechatronics 2/2 : High Power

170 A peak

Valeo power module with DBC technology for

high performance
Fully removable EPS with IP protection
guarantee after 3 disconnections
(Over-molded die-casting, limp sealing,
sliding
connector)
Confidential March 31th, 2016 I 8
Property of Valeo. Duplication prohibited
 Power Steering
170mm MAX

142mm MAX

Ø 93mm max
Power Pack (140A)

45mm MAX
Cover Connector

Control Board

Power Board

Heat Sink

Motor
System Control Power Mecha
Process
+ Scalable + Standard FR4 + Thick copper FR4 + Simply process
architecture for motor + Optimized + D2PAK Mosfet + Robust concept
from 2,5Nm to 4,5 architecture based + Common EMI based on well known
Nm on Aurix platform inductor for DM & CM technologies
+ Torque ripple (+ Possible SW with filter
+ EMC Class 5 safety concept)
+ High integration

Possibility to provide a complete powerpack

Buy motor, make electronic, assembly both

Confidential March 31th, 2016 I 9

Property of Valeo. Duplication prohibited
 Power Steering
Common platform of control
Core functions from Infineon
MOT_TEM
BATTERY + (KL30) Bridges Phase P
KL3 MOT_TEMP_GND NTC
(Mosfet) switche

New µC AURIX (INFINEON)

0
GND Power s
KL3 (KL31) module (Mosfet
1
EMC )
Suppl SH_U SH_V SH_W PH_U
PHASE_U
Filter PHASE_V

New Power SBC (INFINEON)

y Shunts
GND
PH_V
GND_FR4 PHASE_
W
MEC PH_W

A NTC SL_U SL_V SL_W MOS_SP_U

MOS_SP_V
MOS_SP_W

Power
DBC_TEMP_GND
Board Interconnections GDU TLE9180 (INFINEON)

MOS_GL_W
SHUNT_PW

MOS_GH_W
MOS_GL_U
SHUNT_PU

MOS_GH_U
SHUNT_NW

MOS_GL_V
SHUNT_PV
SHUNT_NU
VCC_3V

SHUNT_NV

M0S_GH_V

MOS_SH_W
MOS_SH_U
MOS_SH_V
3 DC_LINK_FILT DC_LINK_IN
DBC_TEMP
DC_LINK_FILT Vbatt DC_LI
NK _S
switche W
VCC_3V
d VDH_UV
3 VCCVS

GATE_P_W
GATE_P_U
GATE_P_V
W VDH_P

Open functionality
ADC_DC_LINK BH_U
DC_LINK_SW VDH_UV
Battery 3-Phase BH_V
W BH_W
VOUT_BUCK_P5V7 measureme ADC_DC_LINK_EXPANDED 3-current
VDH_ MOS Driver voltage
nt P measureme
feedbac SOFF
P5V_VCC_CO nt
k
NV
ENAINH ERR

DBC_TEM
Power
module
ADC_DBC_TEMP GDU
With or without comfort functions
ADC_Phase_Current_W

P
Temperatur

GDU_PHASE_W
GDU_PHASE_U
ADC_Phase_Current_U
ADC_Phase_Current_V

GDU_PHASE_V
ADC_GDU_OFFSET

GDU_SPI_SCLK
GDU_SPI_MISO
GDU_SPI_MOSI
GDU_PWM_HS_W
GDU_PWM_HS_U

GDU_PWM_LS_W
GDU_PWM_HS_V

GDU_PWM_LS_U
GDU_PWM_LS_V

GDU_SPI_CS*

DC_LINK_SW
e M_SUPPLY_SAFE_STATE

• Limp home, limp aside

CPU_GDU_INH*
CPU_GDU_ENA

GDU_ERROR*
measureme
nt
VOUT_BUCK_P5V7 VCC_3V3

SPC_IN SPC_DATA1 SBC_PHASE_SWITCH_OPEN_EN

SENT

With or without embedded phase mosfet

1 SPC_DATA2
1 SPC_IN SENT CPU_FS0_LO 3x Phase
SENT SPC_TRIGGER1
2 Conditioner W
2 SPC_TRIGGER2
DC_LINK_FILT_OR_VOUT_BUCK_P5V7
switch driver
CPU_PHASE_SWITCH_OPEN_U
ADC_DC_LINK_EXPANDED CPU_PHASE_SWITCH_OPEN_V
DC_LINK_IN DC_LINK_FILT ADC_DC_LINK CPU_PHASE_SWITCH_OPEN_W

Sensor
DC_LINK_FILT_OR_VOUT_BUCK_P5V7 BOOS
T VOUT_BUCK_P5V7
BUCK
VCC_5
V
SBC_PHASE_SWITCH_OPEN_EN P5V_VCC_CO
NV
With or without reverse battery protection
s VOUT_BUCK_P5V7 RPS1_SIN
VST VCC_3V 1V
QUC 1V 
3

Communication by CAN, CANFD or Flexray

P5V_VCC_CO 3 3 RPS1_SIN
TORQU P5V_SENSOR_1 QVR 
E QT1 NV TMR
PS1 SCS
M_SUPPLY_SPI_B_CS Main RPS1_COS
sensor 1
AN_SNS_SUP_1 M_SPI_B_CLK 
PS1 Power supply SCL µC RPS1_COS
meas. M_SPI_B_RX 
TORQU & SDO AURIX Rotor
Angle sensor or Sleep Mode (<100µA)
P5V_SENSOR_2 M_SPI_B_TX
E QT2 Safety SDI TC234L
PS2 M_SUPPLY_INT
RPS2_SIN Magn
AN_SNS_SUP_2 TLF3558 INT (INFINEON 
PS2 meas.
4 ER M_SUPPLY_INT
)
RPS2_SIN  et
P5V_CAN
TMR
R V_STBY
QCO
QST RPS2_COS sensor 2
KL1
5
KL15 WAKEUP_KL15
ENA
ROT
M_SUPPLY_RESET_OUTPUT

SS1 M_SUPPLY_SAFE_STATE

RPS2_COS

Mot
1 or 3 shunts
P5V_VCC_CO
SS2
NV
or
Resolver, AMR, GMR, TMR, Hall position
Brake Brake light Brake light Trig Motor
signa DC_LINK_FILT ADC_MOT_TEMP
light
Vehicl l M_SUPPLY_SAFE_STATE
DC_LINK_FILT_OR_VOUT_BUCK_P5V7 Temperatur
MOT_TEMP
Legend
sensor
e
e CAN CANH P5V_CAN CAN_RX
CAN measureme Common brick MQB2020/EBKV2020
CANL CAN_TX
/ nt
Brick dedicated for MQB2020
flexra DC_LINK_FILT_OR_VOUT_BUCK_P5V7 xtal1 xtal2 VSS
y Brick dedicated for EBKV2020

With or without redundant position sensor

VBAP5V_CAN
T
BP VCCVCC_3V3
flexra FLEXRAY_RX Common architecture but differents
FlexRay
OSC_XTAL1

OSC_XTAL2

BM
VSSOSC

FLEXRAY_T components to have a lean design

y
AN_SNS_SUP_1

AN_SNS_SUP_2

VOUT_BUCK_P5V7

VIO
TJA1081 X
ADC_DBC_TEMP

FLEXRAY_EN
Two separates boards for
FLEXRAY_RXEN MQB2020
M_SUPPLY_SAFE_STATE
BGE FLEXRAY_TR_E

Digital or analog torque sensor signal

N*
FLEXRAY_ER Crysta
Control
One common board for EBKV2020
R*
FLEXRA Y_ST l
Connect B*
(G3)

or board One connector for EBKV2020 which

includes the three connectors
Connector

Open architecture of control with several available options

Confidential March 31th, 2016 I 10

Property of Valeo. Duplication prohibited
 Power Steering
HW Safety concept Serie MOSFETs to disconnect the
motor phases

MOSFET DRIVER

DIAG

CPU PHASE
SWITCH
Power SBC
=
RESET
SUPPL
Y
+ Voltage monitoring (SPI)
MOTOR
POSITION
SUPERVISOR
+ Watchdog (SPI)
VOLTAGE
MONITORIN FCCU
G
+ Link only if
SAFETY FS0 (Failure Signal) FS0 signal is
inactive

ASIL D compliant
Guarantee by Infineon architecture (Lock step µC – Power SBC – Smart
Driver)
Confidential March 31th, 2016 I 11
Property of Valeo. Duplication prohibited
 Power Steering
SW / Building Block strategy

Applicative Layer
Interface Layer
System Services Memory Services Communication Services I/O HW Abstraction Complex
Com Nm Drivers

CAN SM
Dcm
If

IpduM

Dbg
ComM
WdgM

BswM

EcuM
CAN
Dem
Csm

FIM

Det

PduR
Dlt

NvM Nm
Bootloader

CanTp IoHwAbs
Xcp
Motor
Stbm

On Board Device Abstraction Memory HW Abstraction Communication HW Abstraction Control

MemIf
CanIf
OS

WdgIf
Ea Fee
CanTrcv

SafeTLib
Microcontroller Drivers Memory Drivers Communication Drivers I/O Drivers (Safety L3)
CorTest

RamTst

FlsTest

Pwm
Wdg
Mcu

Port
Can

Adc
Gpt

Eep

Dio
Spi
Fls

Icu
Microcontroller

On-going development ElektroBit/Valeo

AUTOSAR Ready (4.x)
Valeo custom Valeo Valeo scope : BSW
Customer Infineon Etas
Confidential March 31th, 2016 I 12
Property of Valeo. Duplication prohibited
 Power Steering
Advanced Project / Building Block strategy
Building Block MP EPS On-going EPS New EPS
600 components 617 components 396 components
CPU+E²PROM+CLK FSL / Leopard AURIX Infineon AURIX Infineon
MOS_GDU GDU infineon /
CURRENT PROCESSING TLE7185E
ENABLE GDU GDU Infineon GDU Infineon
OVER VOLTAGE PROTECTION X
PHASE_VOLTAGE_MEASUREMENT X
LS_SHUNT_MEASUREMENT X X X
PHASE SWITCH CONTROL NA X Potential ASSP
MAIN SENSOR X (AMR) X (Resolver)
HALL SENSOR X NA
New Building Block
SECONDARY SENSOR X (GMR) NA
Position sensor & Sleep
SLEEP MODE FUNCTION X NA mode
HALL SENSOR_PSU X NA
SLEEP MODE PSU X NA
FLYBACK X
SUPERVISORS X
Power SBC 1
SAFTY µc X
Infineon
KL15 X
CAN X
Power SBC 1
ANA_IN_PCB_TEMP_MEAS X X Infineon
REF_2V5 X X
PHASE TIMER NA X
ANA_IN_TEMP_MEASUREMENT X X
LV_MEASUREMENT_DC_LINK X X
DC_LINK_SWITCHED X X

New building blocks to go to more integratio n

Confidential March 31th, 2016 I 13
Property of Valeo. Duplication prohibited
 Power Steering
Phase Mosfet control : 3 solutions with 2 independent control paths
Valeo Patent
1 2 3

Cost (++) – Safety () Cost (+) – Safety (+) Cost () – Safety (++)

From µC path From µC path From µC path

Control each phase Control each phase Control each phase
independently independently independently

Opening at 0 current Opening at 0 current Opening at 0 current

From Power SBC path
Immediate opening (no
timer) of all phase switches
Opening up to max phase
current in avalanche mode
From Power SBC path
Delayed opening (passive
or digital timer) of all
phase switches
Opening on limited phase
current in avalanche mode
From Power SBC path
Immediate opening (no
timer) of all phase switches
Opening up to max current
in linear mode

Confidential March 31th, 2016 I 14

Property of Valeo. Duplication prohibited
 Power Steering
Phase Mosfet control – Linear Phase Switch
Opening

Test configuration : 180µH self & 200A immediate opening

Linear mode opening
is triggered 500µs after
GDU OFF with 150A
still in the coil

Current is back to zero

Amps in 5.5ms after
linear mode operation
is started

Joules dissipation
timing is configurable
(-> to set maximal
thermal elevation vs.
worst case )
Valeo patent

Confidential March 31th, 2016 I 15

Property of Valeo. Duplication prohibited
 Power Steering
Input
Position sensor
& sleep mode 1 magnet / one pair of pole
Maximum motor speed 3800
RPM (function of the application)

RPS requirements
ASiL D
Main sensor with high accuracy : 0.1°
(Without processing)
Redundant sensor for lower
accuracy accepted : 4° (Without
processing)

Sleep Mode requirements

ASiL D
Rotor rotation counter resolution
Enough accuracy to define the sense of
Several available solutions to fill the the rotation
OEM Consumption lower than 100uA
requirements
Lost battery detection
Confidential March 31th, 2016 I 16
Property of Valeo. Duplication prohibited
 Power Steering
Position sensor
Resolver
10kHz excitation wave, several impedances.
Secundary Sin/Cos acquisition ASIL D compatible

AMR/GMR
180°/ 360° sensor with Hall switch IC for dual 360° sensor
Fits for sleep mode function need Magnet

Analog acquisition Switched Hall

Dual Die

TMR Valeo patent

Dual 360° sensor, low power consumption

Ideal for applications with sleep mode
Analog acquisition
M
a
g Dual Die
360° ratiometric sensors in several Valeo products. n
e
Analog acquisition t
Hall
Confidential March 31th, 2016 I 17
Property of Valeo. Duplication prohibited
 Power Steering
Sliding motor phase connector

Characteristics
4 contact points
Flexible design to absorb
mechanical constraints limited by
ribs
Electrical welding on bus bar

Advantages
Contact point with a spherical contact
to have repetitive contact resistance
Maximum spherical radius to reduce
the contact resistance with minimum
stress on treatment
Contacts design accepts the
tolerances of motor tab localisation

Valeo patent
Robust and removable motor terminal
Confidential March 31th, 2016 I 18
Property of Valeo. Duplication prohibited
 e-Brake
Derivative EPS
Standard power brake system E-Brake system

Calculation of
assistance Signal
force Mecha
power
Hydaulic
Generation of
assistance
-Replace Master force
Vac by e-BKV Activation of
- Remove the hydraulic
brake
Vacuum
Pump

Transmi Force
Force
ssion sensor
sensor
Pedal
Hydraulic
piston
E-BKV Brake
Vacuum source activation by
Master Vac actuation the driver
force
Vacuum Power
Booster

Power brake system multiplies the force applied on The force applied on the pedal is multiplied by an
the pedal thanks to a brake booster using vacuum electric motor by an ECU.
from the engine.
Vacuum pump independent
Vacuum pump dependent
- Stop-start inhibited when too high pressure (Extended Stop-Start & Coasting)
in Brake/Regen repartition control (Optimized regen)
the Master Vac Very dynamic emergency braking
- Coasting limited @ 20km/h for safety reason
Confidential March 31th, 2016 I 19
Property of Valeo. Duplication prohibited
 e-Brake
Derivative EPS
Mechatronics
Architecture of Power Integrated to motor
Similar
-3-Ph inverter to drive with EPS
PM Machine
- From 400W to 800W
-Power on FR4 with Similar
discrete mosfet with EPS
-No Phase Mosfets of
protection

Architecture of control
- ASIL C product
- Standard
technology on FR4
subtrate
Similar
with EPS
Architecture of SW
- AURIX µ-controller High synergy with EPS
- AC brushless motor control Similar No difference with an EPS Entry Range
law with EPS
- Motor speed up to 5000 rpm
Confidential
Property of Valeo. Duplication prohibited
March 31th, 2016 I 20
 Power Steering
Advanced project : Autonomous driving

Final fallback depending on autonomous level

Level 1 and 2, Fail-Safe capability
Level 3, Limited Fail-Operational capability (maintain the function for 10s) : LIMP
ASIDE Level 4 and 5, Full Fail-Operational capability : LIMP HOME

Confidential March 31th, 2016 I 21

Property of Valeo. Duplication prohibited
 Power Steering
Advanced project : Autonomous driving

Safety
Level 1 and 2 mechanism

Fail-Safe capability Nominal

function
Level 3
Limited Fail-Operational capability
Maintain the function during at least 10 seconds (value to
be confirmed)
Safety
Level 4 and 5 mechanism

Full Fail-Operational capability

Nominal
function

Confidential March 31th, 2016 I 22

Property of Valeo. Duplication prohibited
 Power Steering
Advanced project : Autonomous driving

Impact of autonomous driving on PEL product

High Impact on No Impact on

architecture architecture

EPS X Product
adaptation
ebKV X needed

iBSG X
Family 2
iStARS readiness X
for level 4-5
Inverter for EV X
DCDC X
On Board Charger X

Confidential March 31th, 2016 I 23

Property of Valeo. Duplication prohibited
 Power Steering
Advanced project : Autonomous driving

+BAT_1
+BAT_2

Steering - ASIL D
ECU
1 EPS - ASIL
D

Braking - ASIL
D

ESP - ASIL B
ECU 2
EBKV - ASIL B

Level 3, Limited Fail-Operational capability (maintain the function for 10s)

- Following the way (EPS)
- Progressive braking (EBKV and/or ESP)

Confidential March 31th, 2016 I 24

Property of Valeo. Duplication prohibited
 Power Steering
Advanced project : Autonomous driving

2 independent
power supplies

2
independent
µC / SBC /
6
phases GDU
motor

2 independent
communication layers

Confidential March 31th, 2016 I 25

Property of Valeo. Duplication prohibited
Confidential March 31th, 2016 I 26
Property of Valeo. Duplication p rohibited