The Evolution of Stop/Start

Systems

VALEO RESERVED
 Housekeeping

Fire Exits & Refreshments

Assembly Point

Toilets Smoking
VALEO RESERVED
 Meet The Team

Stewart Lynch Jack Lavell Stephen Knight

Technical Trainer Technical Trainer Division Trade Marketer

VALEO RESERVED
 Agenda

Overview Of Stop/Start Technical Evolution of

1 4
Systems Valeo’s Solutions

Advancements Towards 48V

2 Historical Background 5
Systems

3 Valeo’s Contributions 6 Conclusion

VALEO RESERVED
VALEO RESERVED
 What does this system do?
Micro hybrids system

The micro hybrids are equipped with a device

that STOPS the MOTOR during the stop phase
and AUTOMATICALLY STARTS
the vehicle maximizing comfort

VALEO RESERVED
 Saving fuel

Benefits are
overwhelming
Longer stopped engine, more fuel
savings

London: 32%

Madrid: 30%

Stuttgart: 12%

VALEO RESERVED 7
 Micro hybrid
Conditions of activation the system

During the stop phase,

The ECU will automatically check 3
conditions:

Security conditions
(doors, belts, tilt of the road, speed ...)
Engine conditions
(T°, battery charge, gear position,…)
Comfort conditions
(A/C, heater, ,..)

ANY FAILURE IN SENSOR will

deactivate the stop-start function

VALEO RESERVED
 Micro hybrid
Periferic accessories
The stop-start function is fully managed
by the engine control unit (ECU)

The stop-start system is managed by:

Specific battery + SPYBAT
Transmission sensors Ensures the increase of variable cycle
Stopped vehicle with neutral + verifies the load constantly
gear

Voltage stabilizer Sensors Vehicle /Engine

Keeps active comfort functions It depends on the strategy of each

(air / co, radio, ...) manufacturer

VALEO RESERVED
VALEO RESERVED 10
A Short History:

1974 - The Toyota Crown, the first vehicle to use the automatic ON/OFF switch -
claiming 10% fuel saving in traffic.

1980’s - The Fiat Regata ES with the ‘City-matic’ system and the
Volkswagen Polo used similar devices

1990’s - The 90’s saw Volkswagen adopt the system in the Golf and Lupo as well as Audi introducing it on the A2.

VALEO RESERVED
VALEO RESERVED 12
 Micro hybrid
Two architectures

The reinforced strater is The alternate-starter

mounted instead of a it's a belt drive start
conventional boot solution

The vehicle is still equipped with a

conventional alternator
VALEO RESERVED
VALEO RESERVED 14
 Batteries
Two types

AGM Batteries:
The Absorptive Glass Mat (AGM) battery shares some design
technologies with the traditional flooded, but additional features
such as:
● Fully sealed and sealed
● "Recombinant" VRLA technology
● Calcium plates
The AGM battery has unique characteristics that differentiate it
from the traditional conventional flooded battery that increases its
overall performance in an automotive application
Improved Flooded Battery (EFB) :
Is based on an improved flooded battery design with enhanced
cyclic durability and greater capacity to accumulate charge current

VALEO RESERVED
 Battery sensor
Spybat

Battery sensor Spy Batt for stop-start systems:Sensor

integrated in the battery mounted on the NEGATIVE
BCS – Spybat
terminal

Function:
● Measures the state of charge of the battery to allow /
inhibit the motor stop

● Based on the voltage and temperature of the battery

Negative pole
● The goal is to increase the availability of the Stop-
Start function

VALEO RESERVED
 Battery
Loss voltage control

Adapts the electric stop-start

architecture to ensure:

ELECTRIC ReStarting POWER

(Monitoring of battery voltage)
CONTINUOUS ECU POWERING
(Engine sensors,… )
SAFETY FUNCTIONS
(lighting , brakes, steering…)
COMFORT SYSTEMS
(Radio, GPS,…)

Loss voltage
VALEO RESERVED
 A way of hybridization
There are three types of hybrid

Full Hybrid Mild Hybrid µ-Hybrid

Prius X6 Bluemotion, Bluefficiency, …

The electric motor TAKES The electric motor An alternator-starter or reinforced

total control of the vehicle ASSISTS the thermal strater ALLOWS START-
engine STOP of the thermal engine
VALEO RESERVED
 48V architecture
48V & mild-hybrid

Plug-in
Start & Stop Micro Hybrid Mild Hybrid Full Hybrid Full Electric
Hybrid

SMART MERCEDES S DS5 HY4

MHD 400 HYBRID AUDI CHEVROLET
308 E-HDI A3 E-TRON VOLT – OPEL
(I-STARS) AMPERA

TOYOTA PRIUS + ELECTRIC DRIVE

HONDA
MAZDA I- INSIGHT + ELECTRIC DRIVE (limited)
ELOOP
GOLF 7
(RE-STARTER) + BOOST
+ REGENERATIVE BRAKING
STOP & START

12V 12 – 24V 48 – 100V > 200V > 300V > 300V

3kW 5kW 15kW 30 - 50kW 50 -120kW 50 – 120kW
VALEO RESERVED
 Restarts
technology

VALEO RESERVED 20
 Restart
Structure
Reinforced solenoid switch
(springs, contactors) 6 brushes with 20mm height +
needle bearing

Greater number of teeth / tooth

design for the ring gear Long contactors

Clip stop arm to

minimize axial
movement
Intermediate flange with
Damping gear ring needle bearing
6 magnetic yokes without shunting
for better switching effect

Durability Energy efficiency Longer life and

& Comfort without voltage drops output capacity

VALEO RESERVED
VALEO RESERVED 22
 StARS
technology

VALEO RESERVED 23
 iStARS
The starter-Alternator, reversible system

The kinetic energy taken from the combustion engine is transformed into
electric energy and stored in the battery similar to an alternator but with
higher efficiency

Alternator mode

Starter mode
The starter-alternator (acting as a motor) transforms
the electric energy from the battery into mechanical energy
The starter-alternator generates the torque required spin the
crankshaft (via the belt drive) and start the combustion engine

VALEO RESERVED
 StARS
Structure
MosFets
Force module

Position sensor

Cover

Heat Dissipator
Control
ASIC
Control
Module

VALEO RESERVED
 Restart 1st generation
ReStart 1st architecture
With voltage stabilizer – DMT (200W / 500W)

On going
The DC-DC is used as an auxiliary battery and
prevents the shutdown of the comfort system
(NAV, radio ...) during the ReStart phase

12V dashboard
K1
AGM/EFB Bateria

DC-DC converter
ReStart

Memoria
vehículo
multifunción

VALEO RESERVED
 Restart 1st generation
ReStart 1st architecture
With voltage stabilizer – DMT (200W / 500W)

STOP MODE

12V Dashboard
K1
AGM/EFB Car Battery

DC-DC converter
ReStart
Memoria vehículo
multifunción

VALEO RESERVED
 Restart 1st generation
ReStart 1st architecture
With voltage stabilizer – DMT (200W / 500W)

ReStart MODE

DC DC voltage
converter
dashboard
12V K1
AGM/EFB Car Battery

DC-DC
ReStart
converter
Memoria vehículo
multifunción

VALEO RESERVED
 Restart 2nd generation
ReStart 2nd architecture
Boardnet voltage stabilization system (DMTr)

On going

By-pass
12V 12V Dashboard
Car ECU
Battery

Stabilizer CA
N
ReStart
Function
controls

VALEO RESERVED
 Restart 2nd generation
ReStart 2nd architecture
Boardnet voltage stabilization system (DMTr)

STOP MODE
By-pass
12V Dashboard ECU
Car Battery

Stabilizer
ReStart
Stabilization
request

Function controls

VALEO RESERVED
 Restart 2nd generation
ReStart 2nd architecture
Boardnet voltage stabilization system (DMTr)

ReStart MODE
It is the stabilizer / accumulator that feeds current to the
CAN system to avoid voltage drops in the
communication network
By-pass
12V Dashboard ECU
Car Battery

CAN
Stabilizer

ReStart Stabilization
request

Function controls

VALEO RESERVED
 StARS
1st Generation
An auxiliary battery allows the ECU to be
supplied during the stop phase Dual battery
(only for StARS)
On going
During the operation of the motor, the StARS
Double Battery Module
supplies the board (battery, comfort function,
services)

12V Dashboard
Battery

Battery AUX

StARS

VALEO RESERVED
 StARS
1st Generation
An auxiliary battery allows the ECU to be
supplied during the stop phase Dual battery
(only for StARS)
Stop Mode
It is the auxiliary battery that supplies current Double Battery Module
to maintain comfort functions and power the
ECU

12V Dashboard
Battery

Battery
AUX

StARS

VALEO RESERVED
 StARS
1st Generation
An auxiliary battery allows the ECU to be
supplied during the stop phase Dual battery
(only for StARS)
ReStart Mode
In start-up mode the StARS is supplied from the
Double Battery Module
auxiliary battery through the battery accumulator
module

12V Dashboard
Battery

Battery
AUX

StARS

VALEO RESERVED
 iStARS
2nd Generation
Centralized voltage stabilization system( DMTC)

On going
Last generation: Architecture with MosFet (diodes) to
manage the super charge accumulator

K2 K3

CAN
Super acumulador

12V Dashboard
K1

Battery

ECU
I-StARS

VALEO RESERVED
 iStARS
Measuring rotor position, relative to the stator

360
° Sensor 1
Sensor 2
Sensor 3

Target
Positioning
View of rotor sensor (x3)
and sensors positions

The precise knowledge of the initial position of the rotor is essential to start correctly the engine due to the
synchronous starting principle.
36
VALEO RESERVED
 iStARS
2nd Generation
Centralized voltage stabilization system( DMTC)

Stop Mode
In the stop mode, the MosFet K2 is open to allow the
car battery to supply the current
Stabilization/Recharging request
K2
K3
CAN
Super acumulador
Voltage management

12V Dashboard

K1

Battery
I-StARS ECU

VALEO RESERVED
 iStARS
2nd Generation
Centralized voltage stabilization system( DMTC)

Start Mode
In the start mode, the super capacitor and the battery current are
added in series to generate more voltage at the start

Stabilization/Recharging request
K2
K3
CAN
Super acumulador
Voltage management

12V Dashboard

K1

Battery
I-StARS ECU

VALEO RESERVED
 Accumulator of energy ultra accumulator
Connection

Terminal "-“

Terminal "+”

E-booster
4 pins

Maximum load: 5.4 Volt (V)

Maximum discharge: 0.5 Volt (V)
Accumulator capacity: 600 Farad (F)
Intensity in discharge: 600 Amps

VALEO RESERVED
 Accumulator of energy ultra accumulator
Connector pins

1 4

Pin 1: Accumulated voltage signal

Pin 2: Unused
Pin 3: Temperature sensor signal "+"
Pin 4: Temperature sensor signal «-»

Before disassembling any part of the circuit, discharge the energy from the
accumulator with the specific tool, after the network is positioned in standby mode

VALEO RESERVED
 48V architecture
48V & mild-hybrid

Plug-in
Start & Stop Micro Hybrid Mild Hybrid Full Hybrid Full Electric
Hybrid

SMART MERCEDES S DS5 HY4

MHD 400 HYBRID AUDI CHEVROLET
308 E-HDI A3 E-TRON VOLT – OPEL
(I-STARS) AMPERA

TOYOTA PRIUS + ELECTRIC DRIVE

HONDA
MAZDA I- INSIGHT + ELECTRIC DRIVE (limited)
ELOOP
GOLF 7
(RE-STARTER) + BOOST
+ REGENERATIVE BRAKING
STOP & START

12V 12 – 24V 48 – 100V > 200V > 300V > 300V

3kW 5kW 15kW 30 - 50kW 50 -120kW 50 – 120kW
VALEO RESERVED
VALEO RESERVED 4
 What is an iBSG?
IBSG for Integrated Belt Starter Generator

Valeo 48V iBSG system – Starter-generator with integrated

electronics
An IBSG is an alternator that has to generate 48V in the
generator, or put in motion like a starter to start the engine but not
only this, other functions can be added :
1. Regen : regulate the voltage at iBSG power terminals

2. Boost : can drive the belt to help the engine in take off
phase

3. Coasting : can drive the belt to help the engine on a fix rpm
to reduce fuel consumption

4. Electric drive : drive the engine via the belt , the

combustion engine is off

VALEO RESERVED
 iBSG Working principle
How does it work?

VEHICLE IC-engine
crankshaft
belt
IBSG 48V network
Storage

Electrical
power
Torque Mech.
power
Electrical
power
12V DC/DC converter
network

Electrical
power
12V
battery Electrical
loads on
12V boardnet
VALEO RESERVED
 iBSG physical description
Description by hardware module

● Power modules with MOSFETs

○ Double three-phase full bridge three power
modules

● Excitation module
○ MOSFETs full bridge

● Aluminum heat sink

● Brush holder specific part

○ Supply the rotor

● Input filtering capacitors

○ Ensure network quality during operation

● Rotor position Hall effect sensor

● Control board with microcontroller on PCB

VALEO RESERVED
 iBSG physical description
3 Mosfet power modules, 6 current sensors and filtering capacitors
1
S Component name

1 Power modules x3 6
2

2 Interface to Brush holder

5
3 Filtering capacitors

4 −BAT48V

3
5 +BAT48V

6 Current sensor ferrite x6 4

VALEO RESERVED
 iBSG physical description
I/O Signal overview

Pin Type Summary Description MUX DIG ANA PWM GND SUP
1 t Control supply (+12V) ignition switch (red) X

2 t ENA switchable logic 12V signal level X

3 NC

4 tu CAN High (green) X

5 t Ground supply (black) X

6 tu CAN Low (yellow) X

−BAT48V
+BAT48V

Signal
connector

VALEO RESERVED
 iBSG physical description

VALEO RESERVED
 iBSG Diagnosing & communication
How is it work?

Machine Mode Request Value Machine Mode Status Value

MASTER_MODE_REQ SCU_MODE_STATUS
A Fault status is not linked to NEUTRAL_ACTIVE 0 (0x00)
a trouble fault code NEUTRAL_REQ 1 (0x01)
NEUTRAL_FAULT 1 (0x01)
CRANK_ACTIVE 2 (0x02)
CRANK_DONE 3 (0x03)
CRANK_REQ 4 (0x04) CRANK_FAULT 4 (0x04)
CRANK_OOR 5 (0x05)
GENE_ACTIVE 10 (0x0A)
GENE_DERATING 11 (0x0B)
GENE_MAX 12 (0x0C)
GENERATOR_REQ 8 (0x08) GENE_FAULT 13 (0x0D)
GENE_OOR 14 (0x0E)
TORQUE_ACTIVE 15 (0x0F)
TORQUE_DERATING 16 (0x10)
TORQUE_MAX 17 (0x11)
TORQUE_REQ 16 (0x10) TORQUE_FAULT 18 (0x12)
TORQUE_OOR 19 (0x13)

VALEO RESERVED
 Case N°1 : Loss of availability of the BSG during the driving cycle + warning lamp
Valeo E-Formation - Diagnosis of the BSG
Renault

Diagnosis No fault code is displayed

Control Mode: Ignition ON engine OFF
Preliminary Check

1- Checks ● If the voltage measured on the BSG + 12 V

Before carrying out any diagnosis
of the BSG, the 12V and 48V
batteries need to be checked to
ensure they are in good working
order.
A weak 12V feed from the battery
will generate spurious fault codes
and will not allow correct diagnosis
of the BSG.
● Measure the voltage and current consumption on
the +APC and +BATT (+12V) lines.
● For +APC, the voltage must be > 5,5V and the
current must be between 1mA and 15mA.
● For +12V, the voltage must be > 5,5V and the
current must be < 3A at 5,5V and < 1A at 12,5V.
● On BSG 48V side and harness side check APC,
12V, consumption and connectors
line is different to the voltage of the 12 V
battery, apply the repair method on the
harness between the BSG 48V and the 12 V
battery.
● If the voltage is NOK, the BSG is operating
normally and the fault lies elsewhere, check
the 12V voltage sources

2- Repair
If current consumption is NOK, or if all measurements are OK, perform the following tests:
● Check the condition of the signal connector and wiring harness
IF OK, or the signal connector on BSG 48V is NOK, then Replace BSG 48V
IF NOK, repair harness
5
VALEO RESERVED
0
 Case N°2 : No communication to BSG + BSG alert + Red warning light
Valeo E-Formation - Diagnosis of the BSG
Renault

Diagnostic Fault Code : 0A4Bh - 0C64h - 0C69h

1- Checks ● Short to ground

● Measure the continuity between the BSG and the ● Battery short circuit
−BAT48V
12V system and chassis . ● General electrical failure
+BAT48V ● Ensure that terminals 1 and 5 of the BSG are ● Circuit voltage out of range
correctly supplied.

Control
1 Connector
2- Repair
If a short circuit is present then Replace the BSG 48V
5

VALEO RESERVED 5
 Case N°3 : No communication to BSG + BSG alert + Red warning light
Valeo E-Formation - Diagnosis of the BSG
Renault
Fault Code : 065Ah
Diagnostic
1- Checks
● Unable to activate the BSG via the diagnostic tool ● System performance
● Permanent fault ● Mechanical performance

2- Repair
If a fault is present then Replace the BSG 48V

Case N°4 : No communication to BSG + BSG alert + Orange warning Light

Fault Code : 2CC1h

1- Checks
● System performance too low or too high
● Unable to activate the BSG via the diagnostic tool
● Mechanical performance out of tolerance
● Permanent fault

2- Repair
If the fault is present then Replace the BSG 48V
VALEO RESERVED
 Case N°13 : No communication to BSG + BSG alert + Orange warning Light
Valeo E-Formation - Diagnosis of the BSG
Renault

Diagnostic
Fault Code : 061Ah
1- Checks
● Check the accessory belt as well as the peripheral ● Performance fault
elements: tensioners and pulleys

2- Repair
Disassemble the BSG 48V and manually turn the pulley, if a resistance point is felt then Replace the BSG
48V

VALEO RESERVED
 Valeo E-Formation - Diagnosis of the BSG All other fault codes are not linked to the BSG but to an annex element
Renault
such as :
Diagnostic ● Power wiring
● CAN communication wiring
● The DC/DC converter
● Engine sensors ( AAC and Crankshaft)
● The 12V service battery
● The 48V power battery
Combustion Engine
Crankshaft
Belt
IBSG
48V On-Board network
48V Battery

Electric power
IBSG Pulley

CAN network

12V On-Board network

Electric power
12V Battery DC/DC Converter Electric power
48V <->12V

VALEO RESERVED 12V Consumers

VALEO RESERVED
VALEO RESERVED
56