Valeo Thermal Systems is on a mission to optimise thermal energy management for cleaner, safer and more reliable mobility, while redefining passenger well-being inside the cabin. To learn more about the big picture and forces driving the demanding automotive HVAC market, we spoke to Guillaume Devauchelle, Vice-President, Innovation and Scientific Development, Valeo Group.
What and where are the market growth opportunities for automotive HVAC?
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Air conditioning in the car is not an option, it is a mandatory equipment.
Air conditioning in the car is not an option, it is a mandatory equipment. Consumer expectations in this domain are more and more demanding, driving automakers towards increased content of HVAC for higher differentiation:
- Rear air-conditioning units for faster time to comfort.
- Multi-zone HVAC for individualised comfort.
- Pollution sensors and high-performance filters for safe cabin air.
- Fragrance diffuser for personalised ambiance.
- Brushless blower motors for energy consumption.
The second market driver is electrification, which means energy scarcity on BEV [battery electric vehicles] and on the other hand high-voltage capabilities. It requires us to implement high-voltage electrical heaters into the HVAC. In this way, Valeo can deliver the heating power, which comes from the engine in a traditional car. The value of the HVAC for EVs [electric vehicles] will thus grow significantly.
EVs also require silent systems inside the cabin and for pedestrians during charging. Valeo pays particular attention to the acoustic optimisation of all its systems to reduce their sound impact in the cabin and outside. These include an innovative solution for quiet, delocalised HVAC in the engine compartment, the optimum vibroacoustic integration of the electric compressor, the new front fan with its brushless motor and finally the use of high-performance acoustic materials in various places.
All of these solutions have reduced noise pollution in the cabin for user comfort and up to 4-dBA noise generated during charging for the comfort of pedestrians around the vehicle.
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By GlobalDataWe are hearing more about driver and occupant well-being and individualisation. In what ways is your thermal business addressing this area?
Passengers’ health and well-being expectations combined with energy-efficient mobility require us to carefully identify the real comfort needs of each occupant. Our challenge is to provide the most appropriate solutions, limiting energy consumption while keeping a high level of personalisation.
How do you see climate control requirements changing in the autonomous car?
Valeo is developing automatic detection of passengers’ thermal environment and individual metabolism thanks to intelligent software.
The car will have to adapt to your needs and your position in the car. In an autonomous car, we cannot continue to fiddle with the A/C control panel to maintain comfort. That is why Valeo is developing automatic detection of passengers’ thermal environment and individual metabolism thanks to intelligent software. Interior cameras and biosensors will be used, offering an adaptive self-operation of climate control.
In addition, the seating position in the cabin will change, moving towards a different cabin air diffusion solution. The cabin space will become key for entertainment. This will drive HVAC relocation and decentralisation to ensure a thinner dashboard. Valeo offers compact and decentralised solutions, able to offer the same performance with smaller packaging.
We understand that the electrification of the HVAC system over the past few years has seen a growing emphasis on intelligent integration and controllability. How is Valeo addressing this?
Electrification requires improved acoustics, minimum consumption while keeping optimum performance. Smart control of all heating and cooling devices to offer the best performance with a minimum energy is Valeo’s vision for the future. We cannot independently control a seat heater and the HVAC. The best control of all surface T° and air conditioning based on an accurate comfort model is our unique Valeo Smart Cocoon concept. It adapts to each unique passenger and enables optimum EV range even in summer and winter conditions.
Reducing packaging (compact design) is another major consideration. Can you make the HVAC any smaller or has it reached a plateau?
The OEM has given us an opportunity to relocate the HVAC and free more space inside the cabin.
Valeo is working on an ultra-compact HVAC while maintaining the same performance. The HVAC can also potentially be decentralised, with smaller volume in the central zone, combined with local units close to passengers. Everything is about optimum cost and performance. Both our architecture and our components are modular.
To what extent is Valeo using simulation tools to optimise the airflow in air conditioning systems?
Digital tools have proven to be relevant for pre-sizing, optimisation and even validation of HVAC performances.
An HVAC is a complex system that requires good compromises between acoustic, thermal performance, energy consumption and packaging. Digital tools have proven to be relevant for pre-sizing, optimisation and even validation of HVAC performances.
Firstly, Valeo uses vehicle thermal system simulation, to size the A/C loop based on cabin size, HVAC components and A/C system architecture, to target optimal comfort for the passenger.
The performances can be rapidly predicted through 3D digital tools, such as CFD for thermal performance and aero-acoustic, or FEA for NVH and structural concerns. The production process is also taken into account during the first development stages. This includes rheology simulation for plastic injection and for an accurate prediction of material properties.
The interest of the simulation lies in its ability to iterate rapidly and even to include optimisation loops. Furthermore, it allows us to include analysis on the robustness of the product, taking into account the variability observed during production. Reliability then becomes part of the standard development process.
Presumably using eyes, voice and hand gestures, it is possible to eliminate buttons from a car’s dashboard. What are your thoughts on the HMI, i.e. using a touchscreen to operate the HVAC controls instead of physical buttons and dials?
Our new Smart Cocoon 4.0, presented at CES in January, will be able to eliminate all buttons/ control panel. The car will anticipate each passengers’ needs and adjust performance accordingly. At Valeo, what was once just a dream is quickly becoming reality.
