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Power in Motion

QMX3.3 MODULE BASED ON-BOARD VEHICLE CHARGER. Stuart Evans Director of Business Development. Power in Motion. Presentation Points. Delta-Q What is an on-board charger? Voice of Customer 2010 Automotive OEM needs Universal Requirements QMX Family Technology Advances Conclusion.

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Power in Motion

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  1. QMX3.3 MODULE BASED ON-BOARD VEHICLE CHARGER Stuart Evans Director of Business Development Power in Motion

  2. Presentation Points • Delta-Q • What is an on-board charger? • Voice of Customer 2010 • Automotive OEM needs • Universal Requirements • QMX Family • Technology Advances • Conclusion

  3. Delta-Q • Tier One supplier to industrial EV manufacturers • 600,000 chargers fielded since 2003, currently shipping at >10k/month • Primary application… 50 – 150 vehicle fleets • In-House Product Design and Development • Sales, Marketing and Customer Service • Auto OEM chargers manufactured and co-marketed through global Tier 1 supplier

  4. AC Grid Connection: A Challenge • Grid issues for AC-DC chargers: • Safety, safety, safety • Agency approvals (UL, CSA, CE) • Power quality • Conversion efficiency • High Frequency Switch-mode design • High Efficiency Power Conversion • Digital Control (Digital power via DSP) • Active Power Factor Correction • Proprietary Battery Charge Algorithms • Regulatory Approvals (UL, CSA, CE) • EMI Compliance • Thermal and Mechanical Design

  5. What is an On-Board Charger AeroVironment Coulomb Tech Eaton ECOtality Leviton Mfg. Schneider Electric Shorepower ... Delta-Q EV charge station or EVSE On-board Charger

  6. Voice of Customer 2010 • “EV battery chargers are now on the critical path” • Need low cost (commodity price) charger • No time for generational change • Must meet long lifetime requirement and other OEM requirements, especially safety • Yet… • EV/PHEV market in its infancy

  7. Voice of Customer 2010 Priced at this volume here Chargers needed here

  8. Universal On-Board Charger Requirements • 1.5kW or 3.3kW or 6.6kW or higher • Connectors: OEM specified (few are common) • Cooling: air or liquid • Mounting location: engine compartment (PHEV) to passenger cabin • With/without LV ~400W auxiliary output during charge • With/without full-time LV DC output @ 1-3 kW

  9. Chicken or Egg? • 1.5kW is adequate for a PHEV with a smaller battery • 3.3kW available at 230-240VAC outlet • 3.3kW on current fleet of passenger car EVs (i.e. Volt, Leaf, i-MiEV) • 6.6kW desired for reduced charge time • Sounds expensive - how big is that battery anyway? • Is the market for 6.6kW chargers large enough to justify a cost optimized design?

  10. Final Design Requirements Utility/External/Safety • Regulatory and SAE standards are still evolving • Risk of missing compliance requirements • Excellent performance under all operating conditions • On and off-board communications

  11. 3.3kW Nominal Power Level Designed to accommodate downsizing for 1.5kW AND Designed to accommodate upsizing to 6.6kW

  12. Common Control • Leverage common control for: • - PFC • - HV DC • - LV DC • - Communications

  13. QMX Prototypes now under evaluation in major Auto markets QMX 3.3 kW Charger and Power Supply • Safety • Reliability • Performance • Easy Integration

  14. QMX3.3 3.3kW charge modules 1 x LV (optional) QMX6.6 6.6kW charge modules 1 x LV (optional) QMX1.65 1.65kW charge module 1 x LV (optional) QMX Family

  15. Prototype to Production 2009 327 x 215 x 92 (6.5L) 2011 272 x 200 x 100 (5.4L)

  16. Tier 1 Delta-Q and Tier One Partnering • Worldwide AC grid experience • Extensive Power Electronics Expertise + • Design for Manufacture (DFM) • Validation & Test • Manufacturing and Logistics = Best in class automotive chargers

  17. Conclusion • Complicated array of diverse requirements • Multiple stakeholders and standards • Control schemes and operating modes not consistent across OEMs • Chargers must come through Auto Tier 1 channel

  18. Thank You Questions?

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