In 2024, Valeo will celebrate the 30th anniversary of its presence in China. The group opened its first locations in 1994 and now operates 35 production sites and 14 research and development centers in the Middle Kingdom, employing more than 18,000 people, including 4,500 R&D engineers. Today, China generates 17% of Valeo's global sales.
3-in-1 E-Axle with a completely new design
At Auto China 2024 from April 25 to May 4 in Beijing, Valeo will celebrate the milestone anniversary with many innovations. These include, for example, the 3-in-1 E-Axle: Valeo's complete next-generation drive system is based on a completely new design. It includes an electric motor, inverter, and reduction gear (with a parking lock or separation function). The basis is the brand-new generation of 800 V SiC inverters, which achieve an efficiency of +5% and an additional power density of +40%. It is also 10% lighter and 20% more compact than the previous generation.
Fourth Generation On-Board Charger
Valeo will also present its fourth-generation on-board charger. In addition to charging the battery, it feeds energy bidirectionally into the charging network and can thus supply the smart grids of the future with energy. The most powerful and compact version, with 40% more power density compared to the previous generation, is being developed for a US automaker.
Predict4Range: Software Solution to Improve Range
Managing battery and motor temperature as well as efficiently maintaining optimal cabin conditions for passengers is key to maximizing range and battery life without compromising thermal comfort. The Predict4Range software predicts and controls the thermal management strategies of electric vehicles for greater and longer battery life. The software integrates real-time data such as outside temperature, wind speed, charging station maps, road elevation, and electric vehicle parameters, and provides up to 24% more range under real conditions compared to conventional thermal management control. Predict4Range also takes daily vehicle usage into account and can consider additional parameters such as routes, driving behavior, and habits to accurately calculate and optimize energy consumption.
Intelligent Immersive Battery Cooling System
The intelligent immersive battery cooling system from Valeo combines a dielectric fluid with an intelligent hydraulic and mechanical architecture to improve the overall performance of electric vehicles in terms of safety, efficiency, charging speed, longevity, and reduced environmental impact. The battery cooling system shortens the charging time by 30%, as the cells are preheated in winter when needed. Additionally, the large structural modules embedding the fluid are made from the thermoplastic composite material Valeo OrganoSheet, which offers robust mechanical impact protection and is as light as aluminum, but 50% less carbon-intensive.
Valeo has developed an ultra-compact and lightweight cooling system for high-performance charging stations, offering a high cooling capacity of more than 4 kW. (Photo: Valeo)
Smart Heat Pump to Improve Comfort and Range
Heating, defrosting, and cooling in the cabin consume energy and can significantly reduce the range. In winter, for example, the vehicle's radius decreases by more than 40% when using an electric heater at an outside temperature of -7°C. To address this challenge, Valeo has developed a compact and centralized smart heat pump with complete integration of cooling and refrigerant components, simplifying the system and creating more space under the hood.
This module offers more than double the energy efficiency compared to an electric heater and enables an extension of the vehicle's autonomy by 38 km at -7°C. In parallel, Valeo is developing a second generation with the natural refrigerant CO2 (R744), which provides a further increase in range by 35 km.
Valeo also offers a heating system for the interior surfaces of the passenger compartment, allowing for a noiseless and more energy-efficient radiant heating as close as possible to the passengers. The Valeo FlexHeater radiant system, intelligently controlled with the HVAC and seat heating system, allows for an additional range extension of 10 km at -7°C in addition to this latest generation heat pump.
The combination of these solutions improves the overall vehicle range in winter at -7°C by more than 83 km. In China, for example, the Aito M5 EV and Chery Exeed are equipped with the smart heating system, while the BYD Song (Plus) DMi features Valeo's direct cooling technology for the battery.
Cooling System for High-Performance Charging Stations
Valeo has also developed an ultra-compact and lightweight cooling system for high-performance charging stations, offering a high cooling capacity of more than 4 kW. Valeo's system also features all-in-one electronics and optimized acoustic performance (65 dB(A)). The Sinexcel charging station, presented at Valeo's stand at the Beijing Auto Show, features the intelligent cooling system.
ADAS: Smart Safety 360
Valeo's holistic ADAS approach enables functions such as Valet Parking and L3 Automated Driving. The range of technologies includes the largest selection of sensors on the market (ultrasonic sensors, cameras, radar, LiDAR), a sensor cleaning system, next-generation domain/zone controllers, and a range of software integration algorithms based on artificial intelligence (AI).
Valeo Smart Safety 360 (VSS 360) is a new turnkey driver assistance system that allows OEMs to offer safety and parking assistance features even in entry-level models. The intelligent front camera is at the center of the architecture. Thanks to its integrated, scalable system approach, Smart Safety 360 combines L2/L2+ ADAS functions that meet safety standards such as the latest GSR and NCAP requirements. Depending on OEM specifications, the front camera can be connected with ultrasonic sensors and radar devices and used as a central computer. This eliminates the need for individual control units, saving costs.
Scala3 Lidar: the cornerstone of autonomous vehicles
Scala 3, Valeo's third-generation LiDAR scanner, reconstructs the vehicle environment in a 3D image from point clouds with an unprecedented resolution in an automotive system of 12.5 million pixels per second (16 times more than Scala 2) and a detection range of 200 meters for poorly lit objects (otherwise 300 meters). This enables automated driving on highways (up to 130 km/h) and in the city. Scala 3 consumes less than 15 W. Its compact form is designed to fit on both bumpers and the roof of vehicles.
In addition to its hardware features, Scala 3 is also equipped with software that enables advanced LiDAR perception and functions such as the detection of objects, lanes, landmarks, blockages, rain and spray, online calibration, misalignment detection, or service calibration.
Interior Experiences
Valeo's Panovision solution offers state-of-the-art display integration with screens cleverly reflected by the windshield. This technology provides good visibility for drivers and passengers. Valeo's Panovision's virtually floating images, combined with the augmented reality head-up display, offer a unique experience for the driver.
The new Zeekr 007, whose front panel and interior lighting modules are presented at the Valeo stand, breaks away from traditional design panels segmented into vehicle segments thanks to its innovative front cover, including a 15 mm high bi-functional lighting from Valeo Thinbilite. It consists of more than 1,700 LEDs and offers an interactive lighting experience in real-time. Valeo also ensures dynamic interior ambient lighting in the Zeekr 007.
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