Hybrid & Electric Vehicle Products

Delphi Power Box

Delphi's Power Box is a self-contained hybrid propulsion system that combines electronic components and a lithium-ion battery to simplify electrification and assembly of mild hybrid vehicles. A drop-in solution that typically fits behind the rear seat, the system is capable of both permanent magnet and induction machine control and can be applied across multiple vehicle platforms and powertrains.

Benefits

  • Building block technologies increase flexibility while helping to reduce cost and complexity
  • Complete system integrated in a single housing
    • Interior mount; typically fits behind rear seat
    • Simplifies installation
  • Simplifies hybridization of non-hybrid vehicle
  • Improves fuel economy by 10-20%
  • External manual disconnect helps facilitate safe, easy service and maintenance
  • Applicable across multiple vehicle platforms and powertrain configurations
  • Proprietary battery management algorithms contribute to longer cell life and increased battery safety
  • Functionality
  • Converts high-voltage DC to three-phase power for traction motor drive
  • Converts high-voltage DC to low-voltage DC power for conventional vehicle accessory loads
  • Converts braking energy to charge battery
  • Battery management controller enables state-of-charge and state-of-health calculations, cell balancing and thermal controls

Single-box hybrid propulsion system includes:

  • Hybrid control unit
  • Motor controller
  • Traction inverter
  • DC / DC converter
  • 120 V Li-ion Battery pack
  • Bus distribution center
  • Battery management controller
  • High-voltage safety interlocks
  • Thermal management subsystems
  • System-ready software for motor and battery control

Availability

  • In production

Specifications

Environmental
  • Air-cooled
  • 80 to 134Vdc input operating voltage
  • -30 to +70°C ambient operation
DC / AC Inverter
  • 120V
  • Three-phase AC motor
  • 20kW peak, vector-controlled
  • Up to 150 amps continuous phase current, with sufficient cooling
  • Peak phase current in excess of 300 amps
DC / DC Converter
  • 1.6kW isolated 120 Vdc to 14 Vdc unidirectional
  • 12.5 – 15.5 Vdc output voltage range
Controller
  • Main processor
    • 32-bit
    • 128 MHz Freescale Viper™
    • 3Mbyte flash, 128Kbyte SRAM
  • Motor control processor
    • 128 MHz Freescale Taipan™
    • 2Mbyte flash, 64Kbyte SRAM

Viper and Taipan are trademarks of Freescale Semiconductor, Inc.