System dynamics

Valeo SVA – Special vehicle applications

Valeo SVA use Romax software and services to achieve a CAE-led design process for eMobility system development

Client: Listed on the stock exchange, Valeo is effective, utilising a robust process which expedites an automotive supplier and partner to automakers development cycles. worldwide. In 2019, the Group generated sales of 19.2bn EUR and invested 13% of original equipment sales Solution: Adopting CAE-led design processes, achieved into R&D. Employing nearly 115,000 people across 33 through gaining knowledge from Romax engineering countries, Valeo create innovative products which experts and using Romax software for comprehensive

contribute to reducing CO2 emissions and developing analysis of integrated electric driveline systems. intuitive driving. Benefits: Eliminating one physical prototyping iteration Challenge: Designing and supplying micro-urban by moving testing to the simulation stage, leading to a eMobility solutions which are versatile and cost- 7-9 month reduction in development times.

84 | Engineering Reality Magazine Air quality targets, agreed by contributing towards increasing solutions (e.g. e-bikes), scooters, governments and enforced demand and mounting pressures. and simple city cars, ensuring by legislation, are driving the competitiveness through reusing and to use electric Jérôme Mortal, Transmission Systems recycling components across the drive systems in higher numbers. Product Group R&D and Electrification product family. Whilst Valeo already Alongside cleaning up inner-city Director at Valeo comments, “The supply a range of e-drive systems, air pollution, the industry is under industry is moving faster now than they have recently focused on low pressure to supply solutions to we have seen in the automotive world power application solutions, intending meet growing urbanisation as before. It is hard to believe that just to develop a product suitable for well as additional factors such as 5 years ago we were working on new multiple applications in order to reach reduced room for car parking. The ICE production plants. We believe that, a broader market. change to the requirements for by 2030, electrified vehicles (mainly e-drive units means a shift in the 48V and BEVs) will make up two-thirds “To keep up with the incredible way they are supplied; whereas of cars worldwide. Our vision is that speed that the industry is moving before they would come directly mobility will be strongly diversified, at, we need tools which enable us from car manufacturers, now these with a range of micro urban electric to simulate very quickly, so that we OEMs are joined in the market by mobility on offer alongside versatile can increase the range of products start-ups and Tier 1 suppliers, all hybrid and electric passenger cars.” we offer,” Jérôme explains. “For this competing to offer e-drive systems reason, we use Romax software and to power the next generation of Tier 1 suppliers, such as Valeo, have services for both gear and electrical vehicles. As these automotive the chance to expand their product machine design, from architecture suppliers move towards new types of portfolio by offering drive systems and layout, to concept and detailed mobility solutions, suppliers are also suitable for a range of applications, design. However, it is also critical expected to work differently with from low power (e.g. e-bike) to high for looking at the system integration OEMs. Whilst previously they may be power (e.g. truck), which can be and allows us to capture critical tasked with supplying simple parts installed into vehicles by multiple electro-mechanical interactions. to precise specification, as systems manufacturers. Valeo’s range of Romax software gives us an all-in-one become more complex, suppliers products covers small mobility environment for comprehensive static are increasingly being asked to work (<50km/hr, <100km), light electric and dynamic analysis of an integrated on a subsystem level, or even on the vehicles, mild hybrids, hybrids, plug- electric driveline system, from a full propulsion system. Concurrently, in hybrids and full electric vehicles component to system level, across electrification, autonomous (which offer high performance at zero the whole development cycle, and driving, connectivity, car-sharing CO2 emissions). Within the small- allows us to move towards CAE-led and reducing battery costs are all mobility range, Valeo develop micro- design processes.”

Volume XIII - Summer 2021 | mscsoftware.com | 85 Versatile micro-urban system evaluation, trying to find the unexpected behaviour, mainly due to eMobility solutions best trade-offs across efficiency, the stiffness of the belt, so we decided performance and gradeability. Our to quickly evaluate some different Valeo were tasked with developing design approach considers multiple solutions, working closely with a low power 48V e-drive system. performance targets simultaneously. suppliers to make sure what we were Their design consisted of a simple The optimisation and variability simulating was manufacturable.” air-cooled system, with power analysis helps us to create high quality from 6-10.5KW, a bespoke modular robust designs, and to move towards a Since Valeo had no experience of transmission, integrated inverter, Right First Time philosophy.” simulating a belt drive, they called and permanent synchronous claw upon the expertise of Romax pole motor (reusing an existing Valeo During initial layout studies, Valeo engineering teams, alongside using motor). Jérôme explains further: “As investigated various solutions and Romax software tools. Romax with most projects, our first steps decided to use a belt drive to connect optimised the model, checked the were to select the optimal reducer the e-motor with the gearbox: a results, performed NVH analysis of ratio and to optimise the consumption, solution which offered great variability the system, and gave training to Valeo trying to find the right type and of ratio while keeping the unit versatile SVA. On discovering a resonance issue size of battery and optimise the full to be installed in multiple applications. caused by a higher order harmonic, efficiency of the system, based on Jérôme Mortal comments: “We a change to the belt drive material basic vehicle data and Valeo motor had a theory that using the belt was found to provide a solution. The and inverter characteristics. We would improve decoupling and design was then validated and verified, use Romax Concept in these early reduce interaction between the two looking specifically at the stress and design stages, which allows us to subsystems.” Although Valeo were bending limits of the system. Jérôme investigate multiple layout options confident this solution would work, Mortal explains: “With the versatility with ease. Later, we use Romax Enduro the first design gave far from the of Romax Enduro, we were able to and Romax Spectrum to perform desired performance – “we observed achieve the required durability at an early stage and, in addition, we were able to freeze the design of the housing early. Everything we simulated in the early stage was confirmed later on by test.”

The project brought together four partners: the vehicle OEM (who provided tests and set the specifications), Valeo (who designed and developed the new e-motor architecture, reusing some existing parts for a competitive and affordable solution), Dana (gear and lubrication design), and Romax Technology (belt drive stage simulation and NVH analysis). Jérôme Mortal comments: “As well as providing great software, Romax provided important engineering support. Romax was integral in optimising the durability while

86 | Engineering Reality Magazine do this now to complement simulation, with approval runs on the testbed to confirm the results of the simulation. Not that long ago we were having to test every single assumption. Now, by the time we get to the A-sample stage, we only test one set of samples before moving to manufacturing. Combining proven software and engineering expertise from Romax gave us the confidence to take the risk of eliminating a full prototype iteration, relying heavily on virtual simulation. With this new approach, we have achieved a 7 to 9 month reduction in development time.”

Valeo SVA delivered the drive unit just 18 months after the start of the project (it was launched in June 2020, and can now be bought in the Citroen AMI One). But even more significantly, Valeo SVA have demonstrated that minimising the noise and vibration and Using trustworthy simulation intelligent use of simulation can allow getting the best efficiency early in the results to eliminate one iteration suppliers to significantly reduce the design process.” of physical prototyping time and cost of developing a new e-drive unit. “We have shown that it The resulting architecture uses one In urban mobility, time to market is is possible to get a new product into type of reducer, one type of machine, key. For new products, typically the production very quickly, in a process and can be packaged in different customers’ aspiration is 2 years. For this which is only made possible through configurations – it has already been project, Valeo were given 18 months increasing virtual simulation, which used for 1 application in the EU, 1 in from concept to start of production. in turn is only possible because the , and 1 in , all using the In order to achieve this significant quality of the Romax simulation same machine and same reducer. reduction in development time, Valeo results gives us the confidence to This new concept for traction had to find a way to accelerate the eliminate tests. We are proud of what machines, which met targets for process. They decided to eliminate one we have achieved, and our customer durability and NVH, benefits from a prototype iteration by using simulation is very happy. We intend to apply this patented invention which makes it to test the system extensively within process and knowledge gained in possible to implement and maintain the virtual environment. Having future projects.” an adapted tension without needing used Romax software for previous additional mechanisms to prevent projects, Valeo had the confidence that slippage on the Poly-V belt in the simulation results from Romax could be powertrain. “Using a belt-drive might trusted: confidence which supported Learn more about Romax Technology: seem a surprising choice, however, their decision to increase the level of www.romaxtech.com it makes the system very versatile virtual testing. for different applications, since it covers a very wide ratio (from 9.2:1 Jérôme Mortal explains: “It is critical to 21:1),” continues Jérôme. “Whilst that we get a robust design from the redesigning systems from scratch for very start, and that we can rely on each application may be the ideal, the accuracy of the results so that modularity is important in order to be we can trust them without having to successful in new urban eMobility. The physically test everything. Tools like system we have created is very simple Romax have allowed us to hugely and cost-effective.” reduce our physical testing – we only

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