Nexteer RFI

Updated Mechanical Design concept

O. Vilain / E.Rigaud - Aug 11, 2015

HF-7761EN_C (2014-06)
(2013-10)
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview

Saginaw May 18, 2015 Lippstadt June 17, 2015

Aug 11, 2015

2 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
 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 Motor / Plastic housing / Heatsink Motor / Plastic housing / Heatsink PCB / Heatsink cover
concept inside / PCB / plastic cover inside / PCB / plastic cover

Battery Yazaki connector RFQ Connector, Existing stand alone

connector integrated into plastic housing RFQ connector

CAN connector Specific connector Same as above Same as above

TOS connector Specific connector Connector (Molex) integrated into Connector (Molex Mini 50)
housing, cable inside powerpack integrated into housing,
cable inside powerpack
Cover / venting Venting element integrated Venting element plugged into cover Open ECU
element into housing Access for calibration given by
Plastic cap inserted into cover venting element opening

Customer motor Change requested by Hella Only a cut of blades is needed. Only a cut of blades is needed
leadframe

Sealing ECU / O-ring placed on motor Gasket placed on ECU (housing) Gasket placed on motor
motor

Electronic 9 MOSFETs 6 MOSFETs (no phase cut off) 6 MOSFETs (no phase cut off)
components 1 reverse polarity protection MOSFET 1 reverse polarity protection MOSFET 1 reverse polarity protection MOSFET

3 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
 NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Concept Overview – Manufacturing Flow Chart

PCB CM choke Capacitors Battery Motor Torque Heatsink Insulator

connector phases connector

PCB double
side population Assembly
(glueing)

Boot loader
flashing Soldering on
PCB
Thermal paste Motor
Panel dispensing housing
separation

(@ Nexteer)
Glue dispensing
ICT for EMC fixation

PCB partial soldering on

Equipped PCB ECU
coating PCB
screwing Assembly
(screwing)

Marking
End of line tests and
packing
4 Confidential ISO 16016
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication Hella delivery

Concept Overview – ECU Structure Nexteer

4 Screws for ECU / Motor group assembling

Heatsink – aluminium die casting + machining

surfaces + thermal paste dispensed

Insulator – to prevent any contact between

motor phases & heatsink

Common mode choke placed on PCB before

soldering

Equipped PCB (power MOSFETs + reverse +

filtering components + logic PCB components)

5 Screws with self threading for PCB pressing

and fixation into heatsink

2 capacitors, battery connector, torque

connector & motor phases are placed on PCB
before selective soldering process

Gasket for tightness between ECU & motor

placed on motor

Motor housing

Thermal paste can be dispensed for better

thermal transfer between ECU and motor
housing

5 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication Hella delivery
Concept Overview – ECU Assembly Details Nexteer

Saginaw May 18, 2015 Lippstadt June 17, 2015

Screw M5 Screw M5
Heatsink Heatsink

Bushing Bushing

ECU housing ECU housing

Gasket
Thermal paste
Gasket (O-ring) Thermal paste

Motor housing Motor housing

Toulouse August 11, 2015

Screw M5
Heatsink (ECU housing)

Gasket

Thermal paste

Motor housing

6 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
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

7 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Products architecture comparison – Delivery stand

Concept August 2015 Concept May/June 2015

Venting element
Heatsink
Cover

Common Screws
mode choke PCB
PCB
Heatsink
Screws

Battery Filtering
Connector*
Plastic
Capacitors housing

Motor phases Sealing

TOS Motor phases

connector

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
NEXTEER - HELLA Meeting - CCA Grey Box Price Indication
Commercial offer comparison

Price indication Aug 11, 2015 Price indication May 19, 2015

Mechanical PCB / Heatsink cover Plastic housing / Heatsink inside / PCB / plastic cover
parts

MOSFET IPLU300N04S4-1R1 (1.15 mOhm) IPLU300N04S4-R7 (0.76 mOhm)

Production Removal of process steps linked to plastic cover and Process steps for plastic cover and plastic housing
plastic housing

Venting element No venting element Venting element quoted

Battery No battery connector/harness in the commercial offer Battery connector in the plastic housing
connector (directed part to be considered ?)

=> Current price reduction estimation round about 7 Euro

9 Confidential ISO 16016 NEXTEER - HELLA Meeting | E-SC | E.Rigaud| Aug 11, 2015