Nexteer_Grey_Box_2015-09-02.pdf status next step

1. Nexteer Grey Box
Status & Next steps
Saginaw, September 01, 2015

2. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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2
Agenda proposal
Short history & overall status
Latest Hella technical proposal
Previous Nexteer questions & concerns
Alternatives / optimization ideas
Cost Break Down & Price Walk
Next steps

3. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Short history
May ’15 “Closed ECU” with integrated connectors headers
with Price indication feed-back : please use required PCB cable attachment
from the RFQ package
minimize changes on the motor and its leadframe
June ’15 “Closed ECU” with PCB cable attachment & cable
feed-back : concerns on the PCB cable attachment
on the MPS calibration and on the EMC layout
End of June Feed-back : Commercial gap by 13 €uros
Early August “Open ECU” with PCB cable attachment cable
Price indication : -7€ feed-back : concerns on the PCB cable attachment &
handling and on the MPS calibration
End of August Request to use PSA qualified connectors headers instead of PCB cable
attachment
As of today “Open ECU” with integrated connectors headers

4. Nexteer Grey Box RFI
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Updaded technical concept :
4
Connectors headers
Cap to be inserted after MPS
calibration @ Nexteer
Heatsink sized for autonomous
thermal management
Torque connector
EMC filter
(Common mode choke and
2 x DC-link capacitors)
Motor connector

5. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Connectors headers
5
Connector Manufacturer Reference Comments
Battery Yazaki 7287-8211-30 Approved by PSA
CAN + Enable Tyco 1801177 Approved by PSA
Torque Molex Mini 50 34792-
0040
Nexteer request

6. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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6
Packaging environment compatibility
ECU design 100% compliant with PSA vehicle packaging space
Connector position and orientation to be agreed by Nexteer
Blue: packaging space from Nexteer:
Hella understanding of the Nexteer provided environment:
ECU only

7. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Direct PCB access for MPS calibration
Hella delivery :
Heatsink with PCB access for calibration
@ Nexteer, after MPS calibration :
Metal cap insertion to close the hole
Heatsink
PCB centering hole for
calibration tool
Cap press-in after
MPS calibration

8. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Direct PCB access for MPS calibration
Hole Φ 15 mm
(exact size to be adapted depending
On Nexteer needles)
Calibration tool scheme
Centering, locating pin in the tool
1 mm spring needles (or more)
14 calibration / tests points

9. Nexteer Grey Box RFI
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Thermal management : usual development methodology
1st step :
2D thermal simulations (Cauer model) + correlation with existing real measurements on
similar configuration
• In static (steady state at one operating point)
• In dynamic (with customer parking or city cycles)
Remarks:
- 2D thermal simulation accuracy: ± 10°C
- Worst case conditions considered
- Experiences show worse 2D thermal simulations results than real measurements
(missing interactions between components, no air convection…)
- Enables a first and rapid dimensioning
2nd step :
3D FEA thermal simulations with ANSYS
3rd step :
Measurements with final ECU configuration

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Thermal performance : dynamic simulation
Torque – speed to Power translation

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Thermal performance : dynamic simulation
2) Insertion into the 2D simulation tool
Heatsink
Junction temp
During
Rotor lock

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Thermal performance : with RFQ MOSFETs
Assumptions :
• Reduced heatsink around 330g
• “Prime” configuration : 84A
• Starting operating temperature : 90°C
• Duration for the static study: 421s
• ECU in stand alone (no contact between heatsink and motor housing for cooling)
• MOSFETs max Rds_on value used for the power losses calculation
• MOSFETs : IPLU300N04S4-R7 ( 0.77 mΩ max @ 25°C)
Results :
• Heatsink temperature increase : 59°C
• Temperature increase between MOSFET junction and heatsink : 23°C
⇒ Final MOSFET junction temperature : 172°C

13. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Thermal performance : cheaper MOSFETs
Assumptions :
• Heatsink around 450g
• “Prime” configuration : 84A
• Starting operating temperature : 90°C
• Duration for the static study: 421s
• ECU in stand alone (no contact between heatsink and motor housing for cooling)
• MOSFETs max Rds_on value used for the power losses calculation
• MOSFETs : IPLU300N04S4-1R1 (1.15 mΩ max @ 25°C)
Results :
• Heatsink temperature increase : 48°C
• Temperature increase between MOSFET junction and heatsink : 33°C
⇒ Final MOSFET junction temperature : 171°C
Conclusion :
Possibility to optimize overall costs by changing the ratio MOSFETs Rds_on / heatsink weight

14. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Motor interface & assembly
Blind assembly of the ECU onto the motor housing by simple press-in (180N max)
“Hella” forks with simple straight motor blades
(details available)
Insertion guided thanks to a forks plastic holder
(see afterwards)
Similar concepts in production for EPS applications
for more than 8 years, like
• Bosch VW Golf – SOP 2006
• Continental – VW BS MLB platform – SOP 2010
• TKP PL7 platform – SOP 2011

15. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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15
Motor interface & assembly

16. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Motor interface & assembly
ECU – motor housing
localization pin
ECU heatsink – PCB
localization pin
MPS
Motor phases
connection
Localization for MPS:
1 mm motor position sensor Forks contact accommodate with 2.5 mm
1 mm for the complete ECU (from Fork to Heatsink reference)
Remaining tolerances for Motor blades localization 1.5 mm
Localization for Motor connection:
Motor leadframe keeper

17. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Motor interface & assembly : motor contacts
17
Motor contacts forks of 2.4mm thick each
2.4mm = 3 x 0.8mm thick :
based on Hella test and qualification
Plastic holder :
- Maintain the 3 forks in position
- Ensures insulation between phases
- Prevent stress on PCB during insertion
Total insertion force of the 3 motor blades is correlated
from Hella forks tests and qualification : 180N max.
Forks are soldered into PCB by selective soldering

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E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Motor Connection Details
No motor leadframe layout change from existing Nexteer design
Only shortened blades for the connection to the ECU
Limited change in motor contacts leadframe cutting tool
Exact motor housing / leadframe holder design to be jointly defined, adapted
Impact on motor contacts leadframe

19. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Motor interface & assembly
Heatsink (aluminum die cast)
(dimensioned for autonomous
thermal management)
Motor housing
(aluminum die cast)
@ Nexteer : Sealing
gasket deposit (RTV)

20. Nexteer Grey Box RFI
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Motor phases current flow – rough layout overview
PCB top available surface (logic circuitry – green area) : 4 300 mm²
No specific risk
of MPS disturbance
due to the
power flows MPS
Motor connector
MOSFETs
CAN connector
contacts
Battery connector
contacts

21. Nexteer Grey Box RFI
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Assembly flow chart
PCB Panel
PCB double
sided population
& AOI
Boot loader
flashing
Panel separation
Connector
plate
Common
Mode
Choke
Motor
contacts
Selective
soldering on PCB
Glue dispensing
for EMC fixation
Selective
soldering on PCB
Equipped PCB
screwing
Thermal paste
dispensing
Marking
and
packing
End of line tests
ICT
PCB partial
coating 2-sides
Capacitors Heatsink
Torque
connector
Motor
housing
ECU
Assembly
(screwing)
(@
Nexteer)

22. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Missing or uncertain information
Confirmation of complete packaging environment compatibility
Requirements on connectors position and orientation ( Battery, CAN and Torque)
Motor interface and motor leadframe / contact unit construction:
Is contact unit capable to withstand the maximum insertion force of 180N ?
ECU specifications
Mission Profile & parking cycle for thermal performance
ECU / Motor housing thermal interface performance
Environmental tests specifications DV & PV assumed @ Hella
SWAAT requirements (hours)
Torque connector :
Nexteer request to use a harness connector through the motor housing.
Is it a correct Hella understanding ? Is it still valid ? Yes
What about sealing ? Inside the gear
Exact CMC geometry : Current design based on Hella assumptions
Nexteer MPS design guide lines
Hella forks electrical resistance

23. Nexteer Grey Box RFI
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Alternatives or optimization ideas
Replace connectors headers by blades welded @ Nexteer
☺ In production on the JTEKT – Continental – PSA BHVH2 platform
☺ Reduced power losses
☺ Reduced space requirements
☺ Reduced overall costs
Additional & more complex assembly steps @ Nexteer
Thermal optimization
• Implement thermal paste on ECU/Motor Interface
• Use exact parking cycles to further optimize heatsink / MOSFETs size
Torque sensor connection replaced by forks / blades principle
☺ Fewer assembly steps @ Nexteer. Lower costs
…

24. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Alternatives or optimization ideas
“µC SW routines” for MPS calibration & Motor phases measurements
☺ Hella understanding : no need for extra HW component
• For instance : MPS interface to the internal E²PROM via SPI interface from the µC
☺ Saves the cap costs, the associated assembly and equipment costs @ Nexteer
• Requires some SW routines to be downloaded through the µC boot loader and
operated from the external tester.
☺ The calibration / test routines in the tester should remain the same. The µC and
the ECU electronics are used to access the required tests points from this tester.
☺ No dedicated PCB area

25. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Current Hella technical status
Nexteer concerns from August 11 :
Cable attachment & cable handling replaced by Connectors headers
Direct PCB access for MPS calibration
Hole considered in the heatsink
Cap to be mounted by Nexteer after calibration
Compatibility between thermal paste & grease used by Nexteer is confirmed
Thermal paste : not a must, only as optimization proposal
In any case, not an issue as long as the base material is the same for both
Need to be sure we consider all & correct constraints
For instance : motor assembly insertion forces, PSA specifications
Several optimization topics, ideas to be assessed :
Thermal design & interface
Forks / blades principle for the torque sensor connection
MPS “SW” calibration & Motor phases measurements after assembly

26. Nexteer Grey Box RFI
E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Updated concept : Cost Break Down
ECU Global Quote
Section I - General Information
Company: HELLA KGaA Program Name/PN: PSA 1V5
Facility: HELLA Romania Date: September 1. 2015
Incoterms: FCA Type of Product: EPS
Currency: EURO Completed by: HELLA
General Notes & Comments: Price indication for Base version Europe.
Section II - BOM Details Value June Value Sep. Difference
Nexteer Directed BOM 10.48 € 10.48 € 0.00 €
Electronic BOM (except Directed BOM) 7.14 € 5.64 € -1.50 €
Mechanical BOM 12.25 € 8.06 € -4.19 €
Material Overhead 4% 1.20 € 0.97 € -0.23 €
Section III - Value Add 1: Manufacturing @ HELLA
Manufacturing Cost 4.29 € 3.20 € -1.09 €
Section IV - Value Add 2: SG&A. Profit. Scrap. etc.
Overhead (Selling. General & Administrative. Profit. Scrap) 6.37 € 5.10 € -1.27 €
Section V - Remaining
Packaging not included
Amortization 1.77 € 1.25 € -0.52 €
Section VI - Final Price 43.50 € 34.70 € -8.80 €

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E-SC PM Global – Sept 1, 2015 – Nexteer Grey Box Status
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Updated concept : Price walk from May to Sept 1
Overall 8.80 € reduction of the sales price.
Flat pricing with no productivity on the directed parts (10.48 €).
E-
BOM
(except
Directed
BOM)
Mechanical
BOM
Manufacturing
Cost
Amortization
Overhead
Difference - 1.50 € - 4.19 € - 1.09 € - 0.52 € - 1.50 €
Removal plastic Cover X X X X
Removal plastic housing X X X X
Change of MOSFET's X X
Target purchased parts X X X
Target project costs X X