December 2018

Electronic

Controllers

Managing complex

functionality teach-in

Key takeaways

Regulations increasingly challenge

OEMs to reduce CO2 and toxic

emissions

Deep engineering know-how with

comprehensive propulsion capabilities

Aftermarket offerings that provide

high quality and reliability to meet

OEM performance standards

Electrification increasing with important

role for combustion; ~ 90% of vehicles

sold in 2030 will still have an engine

GDi system solutions are growing as

OEMs shift from light duty diesel

Innovative portfolio of solutions,

designed around the propulsion

challenges of today and tomorrow

1

Driving the next era of propulsion

2

Summary from previous teach-ins

Vehicle electrification required for power & regulatory requirements

Software & control is a critical element of advanced propulsion

Systems integration capability is a necessity for optimum performance

Increased computing power for real-time control

Propulsion controllers for expanded functionality & connectivity

Patented power electronics innovation enabling smaller, lighter & cost effective solutions

A full library of Propulsion Apps for control & diagnostics

System knowledge & integration capability for compliance and performance

More “intelligence” is required for future vehicles

Vehicle complexity and content is increasing

Delphi Technologies has differentiated engineering expertise

Power electronics combined solutions

3

Differentiated thermal management capability enables high performance with flexible packaging solutions

Battery

chargingDC-to-DC

Converter

Starter Generator

inverter

DC-to-DC

Converter

Propulsion

Inverter

Hybrid control

unit

Combined Charger & DC/DC Converter Dual Inverter with DC/DC and Hybrid Control Unit

Automotive content & complexity driving software demand

4

Computing Power System Complexity

2010 20182003

900125

25

Processing speeds (Megahertz)

103

0.3

Memory (Megabytes)

350+175

100

ECU pin count

15001200

900

Software Apps

2003 2010 2018

Engine control software code doubles every 3 years; 1 million lines of code in today’s ECUs

Propulsion controller enables intelligent driving

5

…and enhances overall system intelligence

Communication Network

Engine Controller Transmission Controller Inverter Battery Management ECU

Propulsion Controller

V2V

V2ICamera

Radar Vehicle to Vehicle

Vehicle to Infrastructure

Cloud

Electronic controllers

6

Also known as an Electronic

Control Unit, or “ECU”

“Silver boxes” packaged out of

view (actually aluminum)

More than 50 ECUs in a

premium vehicle

…are automotive computers

From Software & Systems Teach-in

The ECU: how it works

7

Real time control to optimize performance

ECU

Commands

Driver

Propulsion Controller

Other Vehicle ECU’s

Electrical signals to Actuators

controlling the engine: fuel injectors,

ignition coils & valvetrain

Sensors read engine conditions and

give feedback on pressure,

temperature, position of crankshaft

and oxygen in exhaust

Software Apps

are loaded into the ECU

Engine

A look inside an electronic controller

8

Automotive grade packaging

Cover

Connector

Housing

Seal

Printed Circuit Board

Vent plug

Printed circuit board assembly

9

…packed with functionality

Chips

(capacitors and resistors)

Integrated Circuits (ICs)

Printed circuit board design

10

Makes several thousand

electrical connections

Optimizes the size and shape

of the ECU

Enhances manufacturing

quality and reliability

Critical to electromagnetic

compatibility

A key element that requires precision and expertise

Printed Circuit BoardCopper “traces”

make the connection

Types of integrated circuits

11

Multiple ICs are integrated to enable controller functionality

Standard ICs

Communication, sensing

& power drivers

Microcontroller IC

Does the computing

Stores software in memory

ASIC or “A-sic”

Application-specific ICs

Specialized & differentiating

Integrated circuit

12

Reduce size

Reduce cost

Add functionality

Silicon

“die”

…condenses thousands of circuit parts

Circuit

Schematic

The birth of a new ASIC

13

ASIC design in silicon Photo of silicon die

Sub-micron geometries of silicon

Very complex

20 “layers” of silicon and metal

100,000 to over 1 million

transistors

Best-in-class features

Delphi Technologies’ in-house ASIC design capability delivers competitive advantage

ASICs and ICs

14

…foundational to electronic controllers

Electronic Controller

Circuit board

ICASIC IC ICASIC ASICMicrocontroller Connector

Chips

Manufacturing an ECU

15

Designed-in manufacturability to ensure high quality production at scale

Surface Mount

Precise placement of

the chips and ICs on

the board

Assembly

Combine the circuit

board and connector

into housing

Final Test

Test the functionality

and sealing of the unit

Automotive grade: a necessity for power electronic reliability

Extreme requirements create a high barrier to entry

16

Vibration

Multiple g-forces

Temperature

-40°C to +125°C

Humidity

~90%

Salt, dust,

dirt, fluids

Lifetime

+10 years

Electromagnetic

Compatibility

The ECU is foundational to power electronics

17

Top cover

Control

Circuit board

Casting

Top cooling rail

Bottom cooling rail

Busbar assembly

Busbar assembly

Power circuit board

Gate drive

Circuit board

Casting

Capacitor

Inverter

ICs / ASICs

ECU

Power Electronics

At least one ECU in every power electronics unit

ECU

Summary

18

More electrification required for

regulatory compliance & functionality

Internal combustion engine solutions

will continue to be required

Systems integration capability is a

necessity for optimum performance

A range of solutions are required

for advanced propulsion systems

More “intelligence” is required

for future vehicles

Delphi Technologies has

differentiated engineering expertise

Vehicle content and complexity

is increasing

Increased computing power is

necessary for real-time control

Propulsion controllers expand

functionality & connectivity

Global automotive electronics

technology leader

System knowledge & capability

for compliance and performance

Aftermarket portfolio to

complement OEM offerings

1 2 3

Thank you

19