NEXTEER_-_Concept_optimization_2015-08-11_V2.pdf

1. HF-7761EN_C (2013-10)
HF-7761EN_C (2013-10)
HF-7761EN_C (2014-06)
Nexteer RFI
Updated Mechanical Design concept
O. Vilain / E.Rigaud - Aug 11, 2015

2. NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview
2 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
Saginaw May 18, 2015 Lippstadt June 17, 2015
Aug 11, 2015

3. 3 Confidential ISO 16016
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview – Updates summary
Concept May 18, 2015 Concept June 17, 2015 Concept Aug 11, 2015
General MD
concept
Motor / Plastic housing / Heatsink
inside / PCB / plastic cover
Motor / Plastic housing / Heatsink
inside / PCB / plastic cover
PCB / Heatsink cover
Battery
connector
Yazaki connector RFQ Connector,
integrated into plastic housing
Existing stand alone
RFQ connector
CAN connector Specific connector Same as above Same as above
TOS connector Specific connector Connector (Molex) integrated into
housing, cable inside powerpack
Connector (Molex Mini 50)
integrated into housing,
cable inside powerpack
Cover / venting
element
Venting element integrated
into housing
Plastic cap inserted into cover
Venting element plugged into cover
Access for calibration given by
venting element opening
Open ECU
Customer motor
leadframe
Change requested by Hella Only a cut of blades is needed. Only a cut of blades is needed
Sealing ECU /
motor
O-ring placed on motor Gasket placed on ECU (housing) Gasket placed on motor
Electronic
components
9 MOSFETs
1 reverse polarity protection MOSFET
6 MOSFETs (no phase cut off)
1 reverse polarity protection MOSFET
6 MOSFETs (no phase cut off)
1 reverse polarity protection MOSFET
NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015

4. NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview – Manufacturing Flow Chart
PCB
PCB double
side population
Boot loader
flashing
Panel
separation
Battery
connector
CM choke Motor
phases
Soldering on
PCB
Glue dispensing
for EMC fixation
soldering on
PCB
Equipped PCB
screwing
Thermal paste
dispensing
Marking
and
packing
End of line tests
ICT
PCB partial
coating
Capacitors Heatsink
Torque
connector
Insulator
Assembly
(glueing)
Motor
housing
ECU
Assembly
(screwing)
(@
Nexteer)
4 Confidential ISO 16016

5. NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview – ECU Structure
Heatsink – aluminium die casting + machining
surfaces + thermal paste dispensed
Gasket for tightness between ECU & motor
placed on motor
Insulator – to prevent any contact between
motor phases & heatsink
Common mode choke placed on PCB before
soldering
5 Screws with self threading for PCB pressing
and fixation into heatsink
Equipped PCB (power MOSFETs + reverse +
filtering components + logic PCB components)
Motor housing
Thermal paste can be dispensed for better
thermal transfer between ECU and motor
housing
4 Screws for ECU / Motor group assembling
2 capacitors, battery connector, torque
connector & motor phases are placed on PCB
before selective soldering process
Hella delivery
Nexteer
5 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015

6. 6 Confidential ISO 16016
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview – ECU Assembly Details
Saginaw May 18, 2015 Lippstadt June 17, 2015
Thermal paste
Screw M5
Heatsink
Bushing
ECU housing
Gasket
Motor housing
Thermal paste
Screw M5
Heatsink
Bushing
ECU housing
Gasket (O-ring)
Motor housing
Hella delivery
Nexteer
Toulouse August 11, 2015
Thermal paste
Screw M5
Heatsink (ECU housing)
Gasket
Motor housing
NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015

7. 7 Confidential ISO 16016
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
New mechanical concept advantage – Gap closure plan
Advantages:
- Reduction of mechanical components number:
plastic housing and plastic cover removed.
- Better thermal performance
larger contact surface between ECU and Gearbox / Motor housing
- Simplified ECU/Motor interface
aluminum machined surface on both side
- Lower potential disturbances of the Motor Position Sensor
motor current lines distant from the MPS
NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015

8. NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Products architecture comparison – Delivery stand
Heatsink
Common
mode choke
PCB
Battery
Connector*
Screws
TOS
connector
Capacitors
Motor phases
Concept August 2015 Concept May/June 2015
Cover
Venting element
Screws
PCB
Heatsink
Filtering
Plastic
housing
Sealing
Motor phases
Thermal surface between heatsink & motor : 1950 mm² Thermal surface between heatsink & motor : 1050 mm²
* Re-use of existing part(s) in production
8 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015

9. 9 Confidential ISO 16016
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Commercial offer comparison
Price indication Aug 11, 2015 Price indication May 19, 2015
Mechanical
parts
PCB / Heatsink cover Plastic housing / Heatsink inside / PCB / plastic cover
MOSFET IPLU300N04S4-1R1 (1.15 mOhm) IPLU300N04S4-R7 (0.76 mOhm)
Production Removal of process steps linked to plastic cover and
plastic housing
Process steps for plastic cover and plastic housing
Venting element No venting element Venting element quoted
Battery
connector
No battery connector/harness in the commercial offer
(directed part to be considered ?)
Battery connector in the plastic housing
=> Current price reduction estimation round about 7 Euro
NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015