Nexteer Grey Box

Updated status
Toulouse, September 9, 2015
Nexteer Grey Box RFI
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
 September 1st “Open ECU” with integrated connectors headers

 September 9th “Open ECU” with integrated connectors headers

(position optimized for better accessibility for the OEM)
E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update
2 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
Open questions from September 1st meeting

1. Connectors headers accessibility for unlocking seems difficult on ECU v5 design

(issued September 1st) : now “rotated” connectors position

2. Test points diameter for MPS calibration to be increased from 1 to 1.8 mm

3. 3 additional test points added for Motor phase measurement during PowerPack
assembly and testing @ Nexteer

4. Risk of ECU shift during ECU screwing on Motor housing

=> ECU locating pins have been stiffened

Items 1, 2, 3 and 4 are integrated into the ECU v6 model

(sent via DDX to Mr Buesing Chris on September 9th)

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

3 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
Open questions from September 1st meeting

5. Hella fork contacts contact resistance values

Contact resistance and temperature values of triple Hella forks connecting system
available in test report “HEF_128”.

6. Field return rate due to forks

We never experienced a field return due to issues with these forks out of roughly 5
Munits (from one location).
Nevertheless we wouldn't draw an immediate conclusion out of this history, as the
mentioned products (Turbocharger, Manifold actuators) might not be sensitive to
intermittent contact failures.

We are more confident and positive about the proposed ECU / motor connection
based on the fact that we intend to use 3 forks per phase which means that it is
extremely unlikely to have simultaneous failures on the 3 forks.

We do not have data from the competition, but have never heard or read anything
about potential issues originating from the ECU / motor connection.

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

4 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
Updated technical concept : ECU design v6

Female connectors
from OEM harness

Cap to be inserted after MPS

calibration @ Nexteer

Heatsink

Connectors headers

Torque connector Motor connector

EMC filter
(Common mode choke and
2 x DC-link capacitors)

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

5 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
ECU design V6: Connectors headers optimization for unlocking access

Connectors locking are

fully accessible

Connector Manufacturer Reference Comments

Battery Yazaki 7287-8211-30 Approved by PSA
CAN + Enable Tyco 1801177 Approved by PSA
Torque Molex Mini 50 34792- Nexteer request
0040

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

6 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
ECU design v6: Packaging environment compatibility

ECU design 100% compliant with PSA vehicle packaging

space including female connectors from OEM harness.

Connectors wires layout and used vehicle packaging to be

confirmed by Nexteer

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

7 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.
Nexteer Grey Box RFI
ECU design v6: PCB layout

Motor connector

Battery connector pins

CAN connector pins

E-SC PM Global – Sept 9, 2015 – Nexteer Grey Box update

8 Confidential. The contents may only be passed on, used or made known with our express written
authorization. All rights reserved.