EPS Nexteer

Mechatronic architecture
EPS Nexteer
Mechatronic architecture

Concepts overview

Packaging proposal

Power stage design

Thermal Management overview

Motor housing interface / cover / sealing

Connector proposal / Lead connection

HW layout first approach

Key components for quotation

EPS Nexteer Valeo proposal:
Concepts overview 2 concepts for 1V5 project

Input from
Concept Scope Nexteer Scope Valeo Open points Objective
Nexteer

A Open concept To validate To have the

- ECU Housing Mission profile
feasability of power stage
(same than motor (Current,
layout according on the main
housing) cycle)
to the current board
- Power & Signal - Electronic board
connector - EMI Filter
- Torque Connector To validate To withstand
Mission profile
- ECU Cover thermal Tj max of
(Current,
- Thermal interface efficiency of the MOSFET of
cycle)
design 175°C

To validate To have the

Mission profile
feasability of power stage
(Current,
B Closed concept layout according on the main
cycle)
to the current board
- ECU Housing
- Power connector To validate To withstand
Mission profile
- Signal connector thermal Tj max of
(Current,
- Motor housing - Electronic board efficiency of the MOSFET of
cycle)
- Torque Connector - EMI Filter design 175°C
- Thermal interface
- ECU Cover Resistivity of
To validate the To propose a
(delivered appart) current ECU
compatibility of connector
(motor
ECU resistivity compliant
connections &
with the motor without
Power
requirement harness
connector)
 Only one package for base and premium design
EPS Nexteer Package compliant with customer 3D model
Packaging proposal “COMBINED PRIME GREY BOX”

Valeo EPS generic design Design to Cost on Valeo EPS Valeo EPS adaptation to
(June 2014) generic design (December 2014) Nexteer interface (April 2015)

Objectives
Very simple integration with functions embedded on board

BOM & development cost reduction

Integration description
Power and command stage on one board

6 layers FR4 board: 70µm outer layers (Thermal management to confirm)

Embedded CM filter & DM filter on board

Embedded Motor connections on board

Dissipation on aluminium heat sink

EPS Nexteer HW Design compliant to fit
on one board
Power stage design

Objective: To have the power stage on the main board.

Solution: Architecture overview

Power stage design on IRMS Premium Design FR4 board : control & power stage
(84A). HEAT SINK
EMC
filter

To confirm with Nexteer mission profile MOTOR

Backup solution:
Architecture overview
Power stage design on Imax Premium Design
(140A)

Power stage will be implemented on a more IMS board : power stage FR4 board : control stage
thermal efficient substrate, such as IMS (Insulated HEAT SINK
Metallic Substrate) to reduce copper tracks width. EMC
filter
Control stage will stay on FR4.
MOTOR
Mechatronic architecture
already in mass production
on HEPS product
EPS Nexteer Heat dissipation on CCA
heat sink
Thermal Management Overview

Objective: To withstand Tj max of MOSFETs of 175°C.

Solution: Architecture overview

Power stage on FR4 board mosfets

FR4 board : control & power stage
Dissipation on CCA heat sink EMC HEAT SINK
filter

To confirm with Nexteer mission profile MOTOR

Backup solutions: Architecture overview

Improve the thermal efficiency of the substrate HEAT SINK
FR4 with copper inserts
FR4 or FR4 with inserts or IMS
mosfets
EMC
IMS
filter
Create a thermal decoupling between motor and CCA
Dissipation on Cover side with heat dissipation ribs
MOTOR
Mechatronic architecture
already on EPS MLBEVO
product
EPS Nexteer Open CCA to allow sensor
calibration
Motor housing interface / cover / sealing
Motor housing interface
Simpler motor housing with circular shape
CCA locating and fixation by 4 screws
Tightness motor/CCA by metallic gasket or
silicone adhesive

CCA design solution

Valeo will deliver an open CCA to Nexteer
to allow sensor calibration
Nexteer remaining processes
Sensor calibration
Motor leads assembly by welding
Silicone adhesive dispensing on cover (to
see material slide for detailled solution)

Backup for concept with thermal

dissipation made on cover
Sensor calibration made by CAN
or Window on top for sensor calibration and
additional cover
EPS Nexteer Connector w/o harness
and welded lead to comply
Connector proposal / Lead connection to motor sizing

Power connector
Solution: Yasaki Y11-095
Isolated Vbat and GND: Compliant with PSA CCA requirement
Access of counterparts compliant with CCA design
Fit inside “Combined prime greybox”
Access of harness to check To confirm resistivity with Nexteer
motor sizing
Vehicle connector 3 ways
Solution: Yasaki 7283-8852-30

Torque connector 4 ways

Solution: Defined by Nexteer

Motor lead Connection

Several solution available and already in mass production in Valeo
Leadframe welded directly on board
Screwing (HEPS)
Electrical welding (EPS R6)
Sliding connector (EPS R5)
EPS Nexteer All components of the
BOM fit within one board
HW layout first approach Validated by HW design

Power connector

Vehicle EMI
Torque
connector Filter

…
connector

….
W Power
Control stage
stage V

Position
Sensor
BOTTOM VIEW TOP VIEW
 Standard technologies
EPS Nexteer in mass production at
Key components for quotation Valeo PEL

Valeo Project reference in mass

Part Quantity Material
production
Aluminium die casting
Heat sink 1 EPS R5, EPS R6, EPS MLBevo
AlSi12(Fe)
Overmolding :
Power connector
1 - Plastic PBT GF30 EPS R5, EPS R6, EPS MLBevo
Vbat, GND
- Leadframe Cu ETP
Overmolding :
Signal connector
1 - Plastic PBT GF30 EPS R5, EPS R6, EPS MLBevo
3 pins
- Leadframe CuZn33
Overmolding :
Torque connector TBC - Plastic PBT GF30 EPS R5, EPS R6, EPS MLBevo
- Leadframe CuZn33
Cover 1 Aluminium 1050A or plastic PBT GF30 ECU V46, ECU V50, ECU V56
ECU V46, ECU V50, ECU V56, EPS
Sealing 1 Silicone adhesive/sealant Dow Corning 7091
R5
Thermal interface Thermal conductive Gapfiller
1 ECU VD46, EPS R6,
Main board / casing Bergquist GF1500
Electronic Board 1 FR4 6-layer / High Tg 170°C / 70 µm / Gold (TBC)
EPS R5, EPS R6, EPS MLBevo, ECU
SMT paste 1 Senju M31
V46, ECU V50, ECU V56…
Conformal coating on EPS R5, EPS R6, EPS MLBevo, ECU
1 Humiseal 1R32 (or 1R32-A)
PCB V46, ECU V50, ECU V56…
EPS R5, EPS R6, EPS MLBevo, ECU
Selective solder flux 1 Pacific IM2009
V46, ECU V50, ECU V56…
EPS R5, EPS R6, ECU V46, ECU
Screws 1 EJOT Altracs Plus M3.5x8 (self tapping) or equivalent
V50, ECU V56