In recent months, a silent revolution is under way on the Côte d’Opale. Here, in Etaples, close to the seaside resort of Le Touquet (Pas-de-Calais), since March Valeo has produced 48-volt starter-alternators, in addition to its 12-volt classics. Seen from afar, the difference is barely perceptible: the craft is just bigger than its cousin. But in reality, its power is much higher: coupled with a battery of 48 volts, which is recharged during braking, and a small electric motor, the system can relieve the engine during acceleration. “What save up to 10 or 15% of fuel consumption,” said Xavier Dupont, director of the Powertrain activity at Valeo.
Order book tripled
Commonly referred to as a “light hybrid”, this low-voltage system is starting to make a mark. At Valeo, the Etaples plant is the second site to produce it, after that of Shanghai in China: its order book has tripled since 2015, to 1.2 billion euros. “We are planning to ship more than 80,000 units this year, or 1% of our production,” says Alberto Santos, site manager. “This rate should increase to 4% from next year, then to 10% in 2021, around 900,000 units.” To cope, the plant had to plant new lines. It has recruited 250 people since 2013, and another 150 new hires are planned this year.
While pressure rises on the builders to limit the polluting emissions of vehicles, 48 volts has advantages. “It is easy to integrate in vehicles for a limited additional cost, between 800 and 1,000 euros,” said Xavier Dupont. “Notably, because the wiring and electronics are relatively simple: in low voltage (less than 60 volts), an electric shock is not fatal.”
Remediation solution
The French equipment manufacturer, which has been offering this system since 2012, saw its orders take off two years ago in the wake of the “dieselgate”. Delphi, Bosch or Continental, have followed suit. The system has already been adopted by several manufacturers, such as Renault (on the Scenic) or Audi (on the A8). Volkswagen or PSA have announced it for their future models. Valeo estimates that 25 million new vehicles sold in 2026 (out of a total of 116 million) will be equipped with light hybridization, including 20 million via 48 volts. He hopes to capture 40% of this market.
“This is a very good pollution control solution for combustion engines, relatively cheap: we estimate that 31% new cars will be equipped in 2030,” said Eric Kirstetter, partner at Roland Berger. For Alix Partners, however, it will not be enough, because its cost / benefit ratio is not optimal: to reduce their CO2 emissions by 5 grams, manufacturers should equip 27% of their fleet (compared with just 4 % for 100% electric).
Valeo has already imagined using the 48-volt system for other uses. The equipment supplier presented at CES in Las Vegas, in January, a 100% electric car equipped with this system, capable of climbing to 100 km / h – unlike unlicensed electric carts that run today. Several Chinese builders are seriously interested. He also presented at the Vivatech show, in Paris in May, a Golf equipped with a light hybrid system, this time rechargeable, allowing to ride 30 to 40 kilometers in all-electric.
While 48-volt systems are strategic for the equipment supplier, Valeo is also focusing on high-voltage systems, which make it possible to run conventional electric motors. At the end of 2016, Valeo created with Siemens a joint venture to benefit from the expertise of the German giant in this area. In February 2018, it announced 10 billion euros in orders. “We are aiming for 2 billion euros of turnover in 2022, “says Xavier Dupont, director of Valeo’s Powertrain business. “It’s a crazy thing: it employs 2,000 people, and we have to hire another 3,000 within 3 years! I have never seen that ! “.