170915_BVH1_Ecotech_Roadmap.pptx see attached documents

1. 1 Copyright 2017, Nexteer Automotive Corporation. All rights reserved.
BVH1 ROADMAP ECOTECH
Sept 15th, 2017

2. 2
OCT 2018 introduction
BVH1 ROADMAP ECOTECH
Commonize Boot
with CMP
T1/T2 decontenting
CAN Comon mode choke
removal
Toshiba FETs
Ti Amplifier
EPCOS Cap
Kimball VA/VE consolidated
WGF reduction
Taigene VA/VE
Bearing
ressourcing
Gen5 Tbar
Upper shaft &
Pinion adaption
for gen5 Tbar
Washer mat
supplier
WIPM
Upper Rotor

3. 3
SOP 10/18
HW changes
Current sense
amplifier supplier
change to TI
Supplier FETs
change to
Toshiba
T1/T2 capacitor
decontenting
Bulk cap
value
change
Kimball proposal: cap/diode supplier change:
- Battery filtering (ignition interface)
- Ground decoupling near mounting holes
- CAN driver supply filtering
- Diode on PS Mosfet
BVH1 ROADMAP ECOTECH
Can Choke

4. 4
SOP 10/18
HW changes
 Changes:
– CH#1 Lower capacitance of bulk cap EPCOS
 3200µF i.o. 3800µF (based on current simulation)
– CH#2 FET change (Trial testing on going, Topic started in MAR17)
 Toshiba FETs i.o NXP (See land pattern diff. Toshiba in blue)
 Minor Land pattern adaption on CCA
– CH#3 EMC Filtering optimisation
 CH#3.1 T1/T2 Torque sensor signal filtering capacitor removal (2nd order contributor to IR01 issue, 1st order: PGF)
 CH#3.2 CAN choke removal (deviation possibility already under investigation)
– CH#4 Kimbal proposals (Cap 1µF, 10µF & diode supplier change to Murata/NXP, same datasheet)
– CH#5 Current sense amplifier supplier change to TI, same datasheet)
BVH1 ROADMAP ECOTECH

5. 5
 CH#6: Optimize quantity of White Gap Filler
 Change:
– WGF allows heat dissipation between components (in yellow on picture below) &
Controller cover. Change aims at removing it where temperature margin is
sufficient
– Impact on Nexteer process only, for WGF dispensing
SOP 10/18
White Gap Filler removal
BVH1 ROADMAP ECOTECH

6. 6
 Rational:
– Improve reactivity to order increases
 Change:
– Change raw material supplier (Nexteer Tier 2)
– Same material & Properties
– Systems ready for test « Fastening tabs (TS30) »
SOP 10/18
CH#7: Lock Washer material supplier
BVH1 ROADMAP ECOTECH

7. 7
 Rational:
– Simplify process by using same boot for CMP & BMPV project
 Change:
– Use CMP boots design.
– Convolute design slightly different
– Interface between rack boot and rack housing is identical, Tie Rods as well?
– Packaging study (center & EOT)
– Validated by CMP during DV3 with Lot D, Lot M, & Lot P of DVP&R
SOP 10/18
CH#8: Commonize Boot with CMP
BVH1 ROADMAP ECOTECH

8. 8
 Change:
– Choose different bearing supplier (See presentation aside)
– PV level parts about to start testing
SOP 10/18
CH#9: Bearing ressourcing
BVH1 ROADMAP ECOTECH

9. 9
 Change:
– Eliminate plastic over molding process and changed to laser welding
– Magnet are captured in pocket by reducing the size of the window on both ends
– Reduced processing and handling to improve quality
– PPAP samples available
– Potential process impacts under investigation
SOP 10/18
CH#10: Upper rotor with welded stacks (WIPM)
BVH1 ROADMAP ECOTECH

10. 10
 Change:
– T-bar is currently produce in US at Nexteer.
– Change aims at producing locally in Europe or internally
– CH#11.1 Improve Gen V process i.o. using Gen VI
– CH#11.2 Potential update on Upper shaft needed
– CH#11.3 Potential update on Pinion needed
– Full PPAP & Component level testing
SOP 10/18
CH#11 Localize Gen V T-bar
BVH1 ROADMAP ECOTECH

11. 11
 CH#11.1 Motor Housing mold update to remove
pedestal (in red) where PGF was removed earlier
 CH#11.2 Motor Housing mold update to
suppress machining operation for surface in red.
SOP 10/18
CH#11 Motor VA/VE
BVH1 ROADMAP ECOTECH

12. 12
SOP 10/18
Impact Summary
BVH1 ROADMAP ECOTECH

13. 13
OCT 2018 introduction : Timing
 Technical assessment
complete by end Jan18
– Thermal/EMC with new CBOM
– Endurance/NVH with new bearing
– Steering Feel impact assessment
for Toshiba FET (timing plan does
not include re-tuning)
 Early kick-off of changes
– by Mid-Nov to hit PV complete
4months prior to SOP
BVH1 ROADMAP ECOTECH

14. 14
OCT 2018 introduction : Timing
 PV Plan
– Electrical only
 Need to be in Saginaw
– Steering feel none-regression test
to conduct with customer
 Customer status
– No official status yet, no pre-
series deliveries agreed upon
– Need to get « buy-in » for PV
completion SOP-4m
 rule is SOP-6m
– Need joint Sales / Engineering
discussion to tie this with 2018
Performance plan
BVH1 ROADMAP ECOTECH

15. 15
OCT 2019 & beyond introduction
BVH1 ROADMAP ECOTECH
Assist Mech housing
and cover changed to
accomodate other
changes
Lower Rotor with
stamped steel
cores
FR4 PHA, with no
plastic support
Motor localized in
Europe
(6) Non Isolated
worm axis
WGF removal
Crimped / glued
cover and removed
CCA screws
Wangin tie rod
investigations
Turns counter
Non Isolated worm axis
Solid coupler

16. 16
SOP 10/19
Motor Localisation & WGF removal
 CH#1 Motor Localisation :
– Localize Motor production in Europe to improve logistics
– RFQ on going with suppliers
– No change of specification
– Impact on Calibration & tuning
 CH#2 WGF removal
– Investigate if complete removal possible with new motor
BVH1 ROADMAP ECOTECH

17. 17
 CH#1 bis: Single Isolated bearing
– CH#1.1 Isolators removed
– CH#1.2 Worm shaft length & geometry
– CH#1.2 One out of 2 Bearings reduced from 32mm to 24
– CH#1.3 Beveled snap ring + External snap ring
– CH#1.4 Compressed Elastomer between Inner & outer washer
on 32mm bearing side
– CH#1.5 Assist Mech housing change
to accommodate reduced worm shaft length
SOP 10/19
CH#1: Simplified worm shaft damping
 CH#1: Fixed worm
– CH#1.1 Isolators removed
– CH#1.2 Worm shaft length & geometry
– CH#1.3 One out of 2 Bearings reduced from 32mm to 24
– CH#1.4 Beveled snap ring
– CH#1.5 Compressed O-ring on 24mm bearing side
– CH#1.6 Assist Mech housing change
to accommodate reduced worm shaft length
BVH1 ROADMAP ECOTECH

18. 18
SOP10/19
CH#2: Solid Motor coupling
 CH#2: Motor Coupling:
– CH#2.2 Solid plastic coupler new design
 Derived from flex coupler design
 Axial length reduction
 Mass/inertia reduction
 Simplified mold
BVH1 ROADMAP ECOTECH

19. 19
SOP 10/19
CH#3: PHA FR4 Step 2
 Change:
– CH#3.1 Removal of plastic housing
– CH#3.2 Flat PCB with step near Lower Rotor area
 Thickness of 1.6mm with step at 0.55mm
– CH#3.3 Header soldered on PCB
– CH#3.4 PHA harness length
– CH#3.5 Assist Mech housing pedestal higher
to accomodate removal of plastic housing
– CH#3.6 Sensor cover bump to accomodate Header
 No interface with AM change
– DEV systems ready
– Thermal shock, vibration, EMC
BVH1 ROADMAP ECOTECH

20. 20
Roadmap
 At concept stage or to be implemented after 10/19:
– Stamped Lower Rotor
 Replace powder metal cores by stamped steel
– Turns counter if PSA interested
– Alternative Tie Rods supplier
– CCA fixation with fewer screws
 Remove CCA holes
 Upgrade Motor housing mold
 Epoxy glue
– Crimped/glued CCA cover
BVH1 ROADMAP ECOTECH

21. 21
SOP10/19
Impact Summary
BVH1 ROADMAP ECOTECH

22. 22
OCT 2019 introduction : Timing
Technical risk assessment
 Motor DV
– Pre-select motor supplier by Mid-Oct17
– Complete component level technical
assessment by April-18
 Components
– « Last call » for drop-in technical
changes for PV built end March-18
 Worm shaft line
– Choice between SIB, fixed or … carry-
over by year’s end 17
BVH1 ROADMAP ECOTECH

23. 23
OCT 2019 introduction : Timing
Launch
 DV planning
– Need to k-o DV suppliers before
technical assessment is complete
– Target is to assemble DV systems, on
Tychy production line, in April-18
 PV planning
– Need to kick-off production tooling
(AsmMech housing, motor and sensor
cover primarly) based on technical risk
assessment
 Customer status
– No official status yet, no pre-series
deliveries agreed upon
– Need to get « buy-in » for PV completion
SOP-4m
 rule is SOP-6m
– Need joint Sales / Engineering
discussion to tie this with 2018
Performance plan
BVH1 ROADMAP ECOTECH