BVH1 Ecotech Roadmap

BVH1 ROADMAP ECOTECH
Sept 15th, 2017
1 Copyright 2017, Nexteer Automotive Corporation. All rights reserved.

OCT 2018 introduction
Gen5 Tbar
Upper shaft &
Pinion adaption
for gen5 Tbar T1/T2 decontenting
CAN Comon mode choke
removal
Bearing Toshiba FETs
ressourcing Taigene VA/VE
Ti Amplifier
EPCOS Cap
Kimball VA/VE consolidated
WIPM Upper
Rotor
WGF reduction
Commonize Boot
with CMP
Washer mat
supplier
2
SOP 10/18 BVH1 ROADMAP ECOTECH
HW changes Kimball proposal: cap/diode supplier change:
- Battery filtering (ignition interface)
- Ground decoupling near mounting holes
- CAN driver supply filtering
Current sense
Can Choke - Diode on PS Mosfet T1/T2 capacitor amplifier supplier
decontenting change to TI
Bulk cap Supplier FETs

value change to
change Toshiba
3
SOP 10/18
HW changes
 Changes:
– CH#1 Lower capacitance of bulk cap EPCOS
 3200µF i.o. 3800µF (based on current simulation)
– CH#2 FET change (Trial testing on going, Topic started in MAR17)
 Toshiba FETs i.o NXP (See land pattern diff. Toshiba in blue)
 Minor Land pattern adaption on CCA
– CH#3 EMC Filtering optimisation

 CH#3.1 T1/T2 Torque sensor signal filtering capacitor removal (2 nd order contributor to IR01 issue, 1st order: PGF)
 CH#3.2 CAN choke removal (deviation possibility already under investigation)
– CH#4 Kimbal proposals (Cap 1µF, 10µF & diode supplier change to Murata/NXP, same datasheet)
– CH#5 Current sense amplifier supplier change to TI, same datasheet)
4
SOP 10/18
White Gap Filler removal
 CH#6: Optimize quantity of White Gap Filler
 Change:
– WGF allows heat dissipation between components (in yellow on picture below)
& Controller cover. Change aims at removing it where temperature margin is
sufficient
– Impact on Nexteer process only, for WGF dispensing
5
SOP 10/18
CH#7: Lock Washer material supplier
 Rational:
– Improve reactivity to order increases
 Change:
– Change raw material supplier (Nexteer Tier 2)
– Same material & Properties
– Systems ready for test « Fastening tabs (TS30) »
6
SOP 10/18
CH#8: Commonize Boot with CMP
 Rational:
– Simplify process by using same boot for CMP & BMPV project
 Change:
– Use CMP boots design.
– Convolute design slightly different
– Interface between rack boot and rack housing is identical, Tie Rods as well?
– Packaging study (center & EOT)
– Validated by CMP during DV3 with Lot D, Lot M, & Lot P of DVP&R
7
SOP 10/18
CH#9: Bearing ressourcing
 Change:
– Choose different bearing supplier (See presentation aside)
– PV level parts about to start testing
170720_PSA_prez_
BMPV_Bearing Supplier cha
8
SOP 10/18
CH#10: Upper rotor with welded stacks (WIPM)
 Change:
– Eliminate plastic over molding process and changed to laser welding
– Magnet are captured in pocket by reducing the size of the window on both ends
– Reduced processing and handling to improve quality
– PPAP samples available
– Potential process impacts under investigation
9
SOP 10/18
CH#11 Localize Gen V T-bar
 Change:
– T-bar is currently produce in US at Nexteer.
– Change aims at producing locally in Europe or internally
– CH#11.1 Improve Gen V process i.o. using Gen VI

– CH#11.2 Potential update on Upper shaft needed
– CH#11.3 Potential update on Pinion needed
– Full PPAP & Component level testing
10
SOP 10/18
CH#11 Motor VA/VE
 CH#11.1 Motor Housing mold update to remove

pedestal (in red) where PGF was removed earlier
 CH#11.2 Motor Housing mold update to

suppress machining operation for surface in
red.
11
SOP 10/18
Impact Summary
PVP&R Ecotech
BVH1 SOP1018
12
OCT 2018 introduction : Timing
 Technical assessment
complete by end Jan18
– Thermal/EMC with new CBOM
– Endurance/NVH with new bearing
– Steering Feel impact assessment
for Toshiba FET (timing plan does
not include re-tuning)
 Early kick-off of changes
– by Mid-Nov to hit PV complete
4months prior to SOP
13
 PV Plan
– Electrical only
 Need to be in Saginaw
– Steering feel none-regression test
to conduct with customer
 Customer status
– No official status yet, no pre-
series deliveries agreed upon
– Need to get « buy-in » for PV
completion SOP-4m
 rule is SOP-6m
– Need joint Sales / Engineering
discussion to tie this with 2018
Performance plan
14
OCT 2019 & beyond introduction
Lower Rotor with FR4 PHA, with no

stamped steel plastic support
cores
Motor localized in
Europe
Turns counter
Assist Mech housing

and cover changed to
accomodate other
changes
WGF removal
Crimped / glued
cover and removed
CCA screws
Wangin tie rod Non Isolated worm axis

(6) Non Isolated
investigations
worm axis
Solid coupler
15
SOP 10/19
Motor Localisation & WGF removal
 CH#1 Motor Localisation :

– Localize Motor production in Europe to improve logistics
– RFQ on going with suppliers
– No change of specification
– Impact on Calibration & tuning
 CH#2 WGF removal

– Investigate if complete removal possible with new motor
16
SOP 10/19 BVH1 ROADMAP ECOTECH
CH#1: Simplified worm shaft damping
 CH#1: Fixed worm  CH#1 bis: Single Isolated bearing

– CH#1.1 Isolators removed – CH#1.1 Isolators removed
– CH#1.2 Worm shaft length & geometry – CH#1.2 Worm shaft length & geometry
– CH#1.3 One out of 2 Bearings reduced from 32mm to 24 – CH#1.2 One out of 2 Bearings reduced from 32mm to 24
– CH#1.4 Beveled snap ring – CH#1.3 Beveled snap ring + External snap ring
– CH#1.5 Compressed O-ring on 24mm bearing side – CH#1.4 Compressed Elastomer between Inner & outer washer
– CH#1.6 Assist Mech housing change on 32mm bearing side
to accommodate reduced worm shaft length – CH#1.5 Assist Mech housing change
to accommodate reduced worm shaft length
17
SOP10/19
CH#2: Solid Motor coupling
 CH#2: Motor Coupling:
– CH#2.2 Solid plastic coupler new design
 Derived from flex coupler design
 Axial length reduction
 Mass/inertia reduction
 Simplified mold
18
SOP 10/19
CH#3: PHA FR4 Step 2
 Change:
– CH#3.1 Removal of plastic housing
– CH#3.2 Flat PCB with step near Lower Rotor area
 Thickness of 1.6mm with step at 0.55mm
– CH#3.3 Header soldered on PCB
– CH#3.4 PHA harness length
– CH#3.5 Assist Mech housing pedestal higher
to accomodate removal of plastic housing
– CH#3.6 Sensor cover bump to accomodate Header
 No interface with AM change
– DEV systems ready

– Thermal shock, vibration, EMC
19
Roadmap
 At concept stage or to be implemented after 10/19:

– Stamped Lower Rotor
 Replace powder metal cores by stamped steel
– Turns counter if PSA interested
– Alternative Tie Rods supplier
– CCA fixation with fewer screws

 Remove CCA holes
 Upgrade Motor housing mold
 Epoxy glue
– Crimped/glued CCA cover
20
SOP10/19
Impact Summary
PVP&R Ecotech
BVH1 SOP1019
21
Technical risk assessment

 Motor DV
– Pre-select motor supplier by Mid-Oct17
– Complete component level technical
assessment by April-18
 Components
– « Last call » for drop-in technical
changes for PV built end March-18
 Worm shaft line
– Choice between SIB, fixed or … carry-
over by year’s end 17
22
Launch
 DV planning
– Need to k-o DV suppliers before
technical assessment is complete
– Target is to assemble DV systems, on
Tychy production line, in April-18
 PV planning
– Need to kick-off production tooling
(AsmMech housing, motor and sensor
cover primarly) based on technical risk
assessment
 Customer status
– No official status yet, no pre-series
deliveries agreed upon
– Need to get « buy-in » for PV completion
SOP-4m
 rule is SOP-6m
– Need joint Sales / Engineering
discussion to tie this with 2018
Performance plan
23

BVH1 Ecotech Roadmap

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BVH1 ROADMAP ECOTECH

Sept 15th, 2017

1 Copyright 2017, Nexteer Automotive Corporation. All rights reserved.

Bulk cap Supplier FETs

– CH#3 EMC Filtering optimisation

 CH#6: Optimize quantity of White Gap Filler

– CH#11.1 Improve Gen V process i.o. using Gen VI

– Full PPAP & Component level testing

 CH#11.1 Motor Housing mold update to remove

 CH#11.2 Motor Housing mold update to

Lower Rotor with FR4 PHA, with no

Assist Mech housing

Wangin tie rod Non Isolated worm axis

 CH#1 Motor Localisation :

 CH#2 WGF removal

 CH#1: Fixed worm  CH#1 bis: Single Isolated bearing

– DEV systems ready

 At concept stage or to be implemented after 10/19:

– Turns counter if PSA interested

– Alternative Tie Rods supplier

– CCA fixation with fewer screws

– Crimped/glued CCA cover

Technical risk assessment

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