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<strong>Global</strong> <strong>market</strong> <strong>review</strong><br />
<strong>of</strong> <strong>starter</strong> <strong>motors</strong> <strong>and</strong><br />
alternators - forecasts<br />
to 2011<br />
2005 edition
Page i<br />
<strong>Global</strong> <strong>market</strong> <strong>review</strong> <strong>of</strong> <strong>starter</strong><br />
<strong>motors</strong> <strong>and</strong> alternators - forecasts to<br />
2011<br />
by Matthew Beecham<br />
April 2005<br />
Published by<br />
Aroq Limited<br />
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© 2005 All content copyright Aroq Ltd. All rights reserved.
Page ii<br />
Single-user licence edition<br />
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Fax: +44 (0)1527 577 423<br />
Email: rebecca.rice@just-auto.<strong>com</strong><br />
Copyright statement<br />
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© 2005 All content copyright Aroq Ltd. All rights reserved.
Page iii<br />
Table <strong>of</strong> contents<br />
Single-user licence edition............................................................................................................. ii<br />
Copyright statement.................................................................................................................. ii<br />
Table <strong>of</strong> contents ........................................................................................................................... iii<br />
List <strong>of</strong> tables .................................................................................................................................... v<br />
List <strong>of</strong> figures ................................................................................................................................. vi<br />
Acknowledgements ...................................................................................................................... vii<br />
just-auto.<strong>com</strong>’s research portfolio .............................................................................................viii<br />
Incredible ROI for your budget – single <strong>and</strong> multi-user licences.............................................viii<br />
just-auto.<strong>com</strong> membership ........................................................................................................... ix<br />
Introduction ..................................................................................................................................... 1<br />
No stopping suppliers now........................................................................................................ 1<br />
Report coverage........................................................................................................................ 2<br />
The <strong>market</strong> ....................................................................................................................................... 3<br />
Market trends ............................................................................................................................ 3<br />
Market players........................................................................................................................... 6<br />
Market shares ........................................................................................................................... 9<br />
Market forecasts...................................................................................................................... 11<br />
Technical <strong>review</strong> ........................................................................................................................... 13<br />
Defining the elements ............................................................................................................. 13<br />
Power-hungry options place unprecedented dem<strong>and</strong>s on automotive charging systems ...... 13<br />
Increased OEM interest in integrated <strong>starter</strong>-alternators… .................................................... 14<br />
…But high cost is still an issue ...............................................................................................14<br />
Mini hybrid approach............................................................................................................... 15<br />
Citroen C3 is first European production vehicle to <strong>of</strong>fer stop-start via a 14-volt belt-driven<br />
<strong>starter</strong>-alternator….................................................................................................................. 17<br />
…Followed by Hyundai Getz <strong>and</strong> Ford Fiesta ........................................................................ 18<br />
Visteon’s belt-driven system can be fitted to almost any vehicle engine ................................ 19<br />
ZF Sachs’ Dynastart will enter production in 2008.................................................................. 23<br />
Ricardo, Valeo <strong>and</strong> Gates develop solution for Ford .............................................................. 25<br />
Full hybrid approach................................................................................................................ 26<br />
New <strong>starter</strong> <strong>and</strong> alternator concepts ....................................................................................... 29<br />
Commercial vehicle applications............................................................................................. 30<br />
Other innovations.................................................................................................................... 31<br />
Manufacturers ............................................................................................................................... 33<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Page iv<br />
Bosch ...................................................................................................................................... 33<br />
Denso...................................................................................................................................... 33<br />
Lucas Electrical....................................................................................................................... 35<br />
Mitsubishi Electric ................................................................................................................... 37<br />
Motorcar Parts <strong>of</strong> America Inc................................................................................................. 38<br />
Prestolite Electric .................................................................................................................... 39<br />
Remy International.................................................................................................................. 40<br />
Valeo....................................................................................................................................... 42<br />
Online sources <strong>of</strong> information ..................................................................................................... 47<br />
Free email newsletters............................................................................................................ 47<br />
Other research reports............................................................................................................ 47<br />
<strong>Global</strong> news <strong>and</strong> feature articles............................................................................................. 47<br />
Search the web ....................................................................................................................... 47<br />
Your feedback ............................................................................................................................... 48<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Page v<br />
List <strong>of</strong> tables<br />
Table 1: Other manufacturers <strong>of</strong> <strong>starter</strong> <strong>motors</strong> <strong>and</strong> alternators...................................................... 7<br />
Table 2: Market value <strong>of</strong> OE <strong>starter</strong> <strong>motors</strong> for passenger cars <strong>and</strong> light truck applications,<br />
Western Europe, North America, <strong>and</strong> Japan, 2000 – 2011...................................... 11<br />
Table 3: Market value <strong>of</strong> OE alternators for passenger cars <strong>and</strong> light truck applications, Western<br />
Europe, North America, <strong>and</strong> Japan, 2000 – 2011 .................................................... 12<br />
Table 4: Denso’s Electric Systems’ net sales, 2000 – 2004 .......................................................... 34<br />
Table 5: Prestolite Electric’s manufacturing facilities worldwide .................................................... 40<br />
Table 6: Valeo’s Electrical Systems Branch facilities worldwide.................................................... 45<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Page vi<br />
List <strong>of</strong> figures<br />
Figure 1: Lucas Electrical’s alternator range.................................................................................... 4<br />
Figure 2: <strong>Global</strong> <strong>market</strong> for OE alternators for passenger cars <strong>and</strong> light truck applications, 2004<br />
(% <strong>of</strong> volume).............................................................................................................. 9<br />
Figure 3: <strong>Global</strong> <strong>market</strong> for OE <strong>starter</strong>s for passenger cars <strong>and</strong> light truck applications, 2004 (% <strong>of</strong><br />
volume)..................................................................................................................... 10<br />
Figure 4: Visteon’s SpeedStart12 ................................................................................................... 23<br />
Figure 5: ZF’s DynaStart ................................................................................................................ 25<br />
Figure 6: Denso’s F1 alternator...................................................................................................... 29<br />
Figure 7: The Bosch T1-Multipower ............................................................................................... 31<br />
Figure 8: Basking in the limelight - Lucas Electrical Rotating Electrics range................................ 37<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Page vii<br />
Acknowledgements<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
○<br />
The author would like to especially thank the following <strong>com</strong>panies for their<br />
assistance in producing this report:<br />
Continental <strong>Auto</strong>motive Systems<br />
Delphi Corp<br />
Denso Corp<br />
Ford Motor Co<br />
Hella<br />
Hyundai Motors<br />
Lucas Electrical<br />
Robert Bosch<br />
Visteon<br />
ZF Sachs<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Page viii<br />
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Page ix<br />
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Introduction<br />
Page 1<br />
Introduction<br />
No stopping suppliers now<br />
According to recent research studies, vehicles are at a st<strong>and</strong>still for one-third<br />
<strong>of</strong> the time while in urban areas. Stop-start systems could help make cities<br />
quieter, boost fuel efficiency <strong>and</strong> reduce exhaust pipe emissions. Stop-start<br />
systems operate by cutting the engine when the driver <strong>com</strong>es to a <strong>com</strong>plete<br />
st<strong>and</strong>still. The engine is switched back on when he/she releases the brake<br />
pedal.<br />
The Citroen C3 was the first European production vehicle to <strong>of</strong>fer stop-start via<br />
a 14-volt belt-driven <strong>starter</strong>-alternator in a <strong>market</strong> that is increasingly<br />
concerned with CO2 emissions <strong>and</strong> fuel economy. Citroen claims overall fuel<br />
economy improvements <strong>of</strong> 6 – 10%, depending on the drive cycle. The beauty<br />
<strong>of</strong> the <strong>starter</strong>-alternator is that it <strong>com</strong>pletely eliminates the need for a <strong>starter</strong><br />
motor by virtue <strong>of</strong> a dual-function alternator-type device.<br />
A few years ago the push for 42-volts appeared to be the main reason for<br />
introducing integrated <strong>starter</strong> generators (ISG). But, for many reasons, the<br />
momentum <strong>of</strong> the 42-volts power-net brigade has been reduced. These days,<br />
the issue <strong>of</strong> fuel economy has be<strong>com</strong>e a major promoter <strong>of</strong> ISG following the<br />
European carmakers’ association decision to self-regulate CO2 emissions<br />
down to a fleet average <strong>of</strong> just 140g/km by 2008. Because there is a direct<br />
correlation between the amount <strong>of</strong> fuel consumed <strong>and</strong> CO2 emissions, this<br />
means a reduction in average consumption from 7.6 to 5.8 litres per 100<br />
kilometres. As the accent has changed, so manufacturers shifted the emphasis<br />
to developing systems <strong>com</strong>patible with existing electrical systems using beltdriven<br />
<strong>starter</strong>-alternators. Clearly, the idea <strong>of</strong> stop-start systems is to save fuel,<br />
cut down noise <strong>and</strong> emissions. Valeo’s 14-volt belt-driven <strong>starter</strong>-alternator<br />
technology delivers up to a 10% saving in fuel consumption <strong>and</strong> no engine<br />
noise <strong>and</strong> zero emissions at st<strong>and</strong>still. Reduced noise levels when re-starting<br />
the engine coupled with extended intervals between refuelling also provide<br />
some significant environmental benefits.<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
The <strong>market</strong><br />
Page 3<br />
The <strong>market</strong><br />
Market trends<br />
The technology used in alternators has be<strong>com</strong>e more advanced in response to<br />
the installation <strong>of</strong> an increasing number <strong>of</strong> <strong>com</strong>ponents such as cell phones,<br />
power windows <strong>and</strong> mirrors, heated rear mirrors <strong>and</strong> seats, air conditioning<br />
equipment, <strong>and</strong> high-powered multi-media systems. Consequently, the humble<br />
alternator has be<strong>com</strong>e a high-tech <strong>com</strong>ponent <strong>and</strong> per unit prices have<br />
increased accordingly.<br />
The main drivers <strong>of</strong> innovation <strong>of</strong> conventional alternators is the requirement to<br />
produce more electric power, more efficiently with smaller sized, lighter units.<br />
According to Jim McCaughey, Marketing Manager at Lucas Electrical, the<br />
most obvious change over the past ten years is the fact that units are getting<br />
smaller, whereas the ampere outputs are getting higher. He told just-auto:<br />
“Typically, the output <strong>of</strong> a unit ten years ago was 55A, whereas today a typical<br />
unit is nearer 90-100A. Some top-line car alternators are now topping 180A<br />
units.”<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Technical <strong>review</strong><br />
Page 13<br />
Technical <strong>review</strong><br />
Defining the elements<br />
The <strong>starter</strong> converts electricity into mechanical energy while the alternator<br />
turns mechanical energy into alternating-current electricity. In other words, it<br />
provides electricity for the vehicle <strong>and</strong> keeps the battery charged. Alternator<br />
output is directly related to frame size, or diameter.<br />
Although the electric <strong>starter</strong> motor <strong>and</strong> alternator has remained virtually<br />
unchanged since it was first invented over 80 years ago, the quest for weight<br />
<strong>and</strong> fuel reduction has triggered a raft <strong>of</strong> refinements.<br />
Magnetically geared <strong>starter</strong>s continue to outweigh the non-geared, preengaged<br />
type because <strong>of</strong> pressure <strong>of</strong> size <strong>and</strong> output. While a <strong>starter</strong> motor<br />
looks like a <strong>com</strong>modity product, appearances are deceptive. The motor has<br />
undergone major technical advances in an effort to improve longevity, <strong>of</strong>fering<br />
more power as well as reducing both weight <strong>and</strong> costs <strong>com</strong>pared to earlier<br />
generations. Significant advances in alternator specifications <strong>and</strong> performance<br />
are also underway, including new <strong>com</strong>pact alternatives. Over the last decade<br />
there has also been an increasing proliferation in the types <strong>of</strong> alternator<br />
available. Like <strong>starter</strong> <strong>motors</strong>, they are lightweight in construction with higher<br />
outputs <strong>and</strong> better reliability than ever before.<br />
Power-hungry options place unprecedented dem<strong>and</strong>s on automotive<br />
charging systems<br />
The increasing use <strong>of</strong> power-hungry options in modern passenger cars, such<br />
as heated seats, quick-defrost glass, electrically powered brakes, steering,<br />
water pumps, heated catalysts <strong>and</strong> advanced powertrains, is placing<br />
unprecedented dem<strong>and</strong>s on automotive charging systems. The traditional<br />
Lundell-type alternator is unable to h<strong>and</strong>le loads <strong>of</strong> this scale, especially at idle<br />
speeds <strong>and</strong> looks set to be replaced by new machines that are 20% more<br />
efficient <strong>and</strong> significantly quieter.<br />
New units currently under development by both major manufacturers <strong>and</strong> small<br />
independent R&D <strong>com</strong>panies are capable <strong>of</strong> generating between 90% <strong>and</strong><br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Manufacturers<br />
Page 33<br />
Manufacturers<br />
Bosch<br />
Starters <strong>and</strong> alternators fall under the auspices <strong>of</strong> Bosch’s Energy <strong>and</strong> Body<br />
Systems division, which covers the whole range <strong>of</strong> equipment for the vehicle’s<br />
electrical system. The division employs 20,000 people in 29 locations<br />
worldwide. In addition to <strong>starter</strong>s <strong>and</strong> alternators, the division provides<br />
technical solutions for <strong>com</strong>mercial vehicles, s<strong>of</strong>tware <strong>and</strong> electronics,<br />
<strong>com</strong>ponents for engine thermal management, climate control <strong>com</strong>ponents,<br />
seating <strong>com</strong>fort systems <strong>and</strong> actuator technology for various assemblies,<br />
mechatronics for side doors, ro<strong>of</strong>s, windscreens <strong>and</strong> rear window cleaning<br />
systems.<br />
Bosch’s alternator product range includes LI-L longlife alternator, T1-MP highpower<br />
units for buses, LI-E, LI-F, <strong>and</strong> the new LI-X generation.<br />
Its <strong>starter</strong> motor line-up includes the R range <strong>starter</strong>s for passenger cars, HE<br />
reduction gear <strong>starter</strong>s <strong>and</strong> HEF <strong>starter</strong>s range.<br />
Bosch manufactures <strong>starter</strong>s <strong>and</strong> alternators at its facilities in Australia<br />
(Clayton), Brazil (Caminas, Sao Paulo, San Martin), Germany (Cottingen,<br />
Hildersheim), India (Naganathapura), Mexico (Toluca), South Africa (Brits),<br />
Spain (Treto), <strong>and</strong> the UK (Cardiff).<br />
Although it has been reported in the trade press that Bosch is moving its<br />
<strong>starter</strong> motor production from Germany to Hungary, a spokeswoman for Bosch<br />
told just-auto that the move has not yet happened <strong>and</strong> that feasibility studies<br />
are ongoing.<br />
Denso<br />
Denso, Japan's largest automotive parts manufacturer, <strong>and</strong> a key member <strong>of</strong><br />
Toyota’s supplier group ranks first or second globally in nearly 20 <strong>com</strong>ponent<br />
categories. Denso’s <strong>starter</strong>s <strong>and</strong> alternators fall under the auspices <strong>of</strong> its<br />
Engine Electrical Systems Product division, itself part <strong>of</strong> the <strong>com</strong>pany’s Electric<br />
Systems business. The Electric Systems business generated XX.X% <strong>of</strong><br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
Manufacturers Page 45<br />
Table 6: Valeo’s Electrical Systems Branch facilities worldwide<br />
Country Location Business Activity<br />
Brazil<br />
Campinas SP<br />
Valeo Sistemas <strong>Auto</strong>mativos<br />
Electrical Systems<br />
Production site<br />
France Angers Valeo Systemes Electriques Production site<br />
France Etaples-sur-mer Valeo Systemes Electriques Headquarters<br />
France Etaples-sur-mer Valeo Systemes Electriques Production site, R&D centre<br />
France Saint Quentin Fallavier Valeo Systemes Electriques Headquarters<br />
France Saint Quentin Fallavier Valeo Systemes Electriques Production site, R&D centre<br />
France Saint Ouen L’Aumone Telma Production site, R&D centre<br />
Germany Valeo Elektrische Systeme GmbH Ruesselsheim Production site<br />
Germany Valeo GmbH Elektrische Systeme Ruesselsheim Sales <strong>of</strong>fice<br />
Germany Valeo Elektrische Systeme GmbH Stuttgart Production site<br />
Germany Valeo Elektrische Systeme GmbH Stuttgart Headquarters<br />
Germany Valeo Elektrische Systeme GmbH Wolfsburg Production site<br />
Germany Valeo Elektrische Systeme GmbH Wolfsburg HQ, R&D centre, sales <strong>of</strong>fice<br />
Japan Valeo Japan Co Ltd Tokyo Sales <strong>of</strong>fice<br />
Japan Valeo Sistemas Electricos San Luis Potosi SLP Production site<br />
Pol<strong>and</strong> Valeo Sylea Pol<strong>and</strong> SP.ZO.O Czechowice Production site<br />
South Korea Valeo Electrical Systems Korea Kyong Ju-City Production site, R&D centre<br />
South Korea Valeo Electrical Systems Korea Kyong Ju-City Production site, sales <strong>of</strong>fice<br />
Spain Valeo Sistemas Electricos SL Madrid Production site<br />
UK Valeo UK Ltd Birmingham Sales <strong>of</strong>fice<br />
USA Valeo Electrical Systems Auburn Hills Production site<br />
USA Valeo Electrical Systems Auburn Hills Headquarters<br />
USA Valeo Electrical Systems Auburn Hills Production site<br />
USA Valeo Electrical Systems Rochester Production site<br />
Source: Valeo<br />
© 2005 All content copyright Aroq Ltd. All rights reserved.
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