Document of Understanding

Design & Development support for 2/3 kW Single Phase EV charger

Submitted to: SELEC

Attention: Mr. Sanjay Pusalkar, [email protected]

Reference: Mail dated: 15th Dec 2021

VER.REL.NO. & DATE

TITLE
(DD-MMM-YYYY)

Design & Development support for 2/3 kW

Draft/28-Dec-2021
Single Phase EV charger

The contents of this document are the sole and exclusive property of L&T Technology Services. They may not be disclosed to
any third party, copied or reproduced in any form or used for any purpose, other than the purpose for which they were provided,
without the permission of L&T Technology Services.
Document History

Ver.
Prepared. By Reviewed By Approved By Remarks/Revision
Rel. Release Date
Prepared Date Reviewed Date Approved Date Details
No

Pankaj kumar Shailendra Shukla Atul Abhyankar

1.0 Draft
28-Dec-21

Selec/ Draft/28-Dec-2021 CONFIDENTIAL Page 1 of 14

Design & Development support for 2/3 kW Single Phase EV charger

Table of contents
1. OBJECTIVE: ............................................................................................................ 3

2. PROPOSED APPROACH: .............................................................................................. 3

3. SCOPE OF WORK: ..................................................................................................... 6

4. ASSUMPTIONS: ........................................................................................................ 8

5. DELIVERABLES AND ACCEPTANCE CRITERIA: .................................................................... 9

6. MILESTONE AND DELIVERY SCHEDULE: .......................................................................... 11

7. EXCLUSIONS: ......................................................................................................... 11

8. INPUTS RECEIVED/REQUIRED: ..................................................................................... 12

9. RISKS & MITIGATION: ............................................................................................... 13

10. DEVELOPMENT TOOLS .............................................................................................. 14

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Design & Development support for 2/3 kW Single Phase EV charger
1. Objective:
Selec would like to design and develop 2kW and 3kW single phase EV charger with natural cooling and forced cooling (FAN)
mechanism respectively considering the same enclosure size.

Selec would like LTTS support for Design, Development and testing for 2/3kW single phase EV charger

Selec requested LTTS to submit proposal for 2/3kW single phase EV charger. This document covers LTTS understanding for
2/3kW single phase EV charger – project scope, approach and list of deliverables for execution.

2. Proposed Approach:
LTTS will execute the Design & Development of 2kW and 3kW single phase EV charger activity from LTTS offshore. LTTS
will execute project on T&M basis.

Selec has decided to go for two different variants (As per LTTS understanding on the specification document shared by
Selec) of the EV charger with the same enclosure size and type.

1.) 2kW EV charger with natural cooling (Ingress protection -IP54)

2.) 3kW EV charger with forced (FAN) cooling (Ingress protection-IP65)

The below image of competitor EV changer is just for the reference, the actual design and looks may vary.

LTTS propose following execution phases for both types of charger.

1. Feasibility analysis– 2kW and 3 kW EV charger

2. Barrack POC [To check the functionality]
3. POC as good as A sample
4. B sample

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Design & Development support for 2/3 kW Single Phase EV charger

# LTTS will submit separate proposal post feasibility for Barrack POC, POC and B sample.

Below will be overall project work flow

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Design & Development support for 2/3 kW Single Phase EV charger

LTTS will form team as per below team structure. Our overall quality system will be as per LTTS quality management
system.

Overall project will be managed by LTTS and take appropriate inputs and approvals from Selec, during execution there may
be some additional activities (Which are not mentioned in the scope) need to perform [i.e. CFD, FuSa, DFMEA …]. LTTS will
submit separate proposal for the same.

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Design & Development support for 2/3 kW Single Phase EV charger
3. Scope of work:
LTTS scope is to Design & Development of 2kW and 3kW single phase EV chargers [Contains ACF+PFC+DC DC converter
+DCF+Control sections] based on the below specifications:

Based on the overall project execution approach mentioned in chapter-2. LTTS will execute project in following phases,
refer high-level List of activities for each phase.
1. Feasibility of product concept - 2/3kW single phase EV charger [HW & Mech]
a. Specification review and query response
b. Topology selection and comparison (Like for DC DC convertor from PSFB or LLC)
c. Topology finalization
d. Design calculation (High level)
e. Mechanical design (High level)
f. Circuit simulation
g. Part identification (Major parts)
h. Part finalization (Major parts)
i. Idea generation/Concept development
j. 3D Modelling of concepts
k. Integration with Hardware components 3D Models
l. Finalise Concept
m. Report - feasibility of Concept
2. Barrack POC (only for functionality verification)
a. Make list of components to be procured for Barrack samples
b. Schematic creation
c. SW design
a. PCB design PCB design [part creation, component placement, routing]
d. Mechanical design for Barrack if required(To test the Barrack POC)
e. 2/3kW single phase EV charger PCB procurement for Barrack POC
f. Assemble Barrack POC Boards
g. Create samples of Barrack POC
h. Module testing
i. Integration testing
j. System testing

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Design & Development support for 2/3 kW Single Phase EV charger
k. Share system test result with Selec
l. Update Barrack POC based on Selec feedback on test result
m. System testing post Selec feedback
n. document - improvement points for POC
o. Dispatch Barrack POC to Selec
3. POC as good as A sample
b. Hardware design changes/improvement
c. Software Design changes/improvement
d. Mechanical design changes/Improvement
e. Schematic upadte
f. Circuit simulation for POC
g. BOM creation for POC
h. PCB design [part creation, component placement, routing]
i. Harness and connector selection and design
j. Mechanical parts design
k. Create 3D model and 2D drawings for Tolerance Stack-up analysis
l. Parts verification
m. Structural analysis of PCB assemblies
n. Gerber release for POC [PCB review and Gerber generation]
o. PCB manufacturing release for POC
p. Prepare component procurement list
q. Component procurement for POC
r. Board assembly
s. POC testing
t. Hardware module testing
u. Integration testing
v. System testing
w. Share system test result with Selec
x. Update POC based on Selec feedback
y. System testing - post Selec feedback
z. Report for improvement points for B sample
aa. POC samples dispatch to Selec

4. B sample (This sample is optional. Will be decided by the mutual agreement between Selec and LTTS. LTTS will
submit the separate proposal for B sample)
a. HW design update
b. SW design update
c. Mecha design update
d. Schematic update
e. BOM update
f. PCB design update
g. Harness and connector selection and design update
h. Mechanical parts design if required
i. Create or change 3D model and 2D drawings for Tolerance Stack-up analysis
j. Parts verification
k. Structural analysis of PCB assemblies
l. Tolerance Stack-up analysis
m. Gerber release for B sample [PCB review and Gerber generation]
n. PCB manufacturing release for B sample
o. Prepare component procurement list
p. Component procurement for B sample
q. Board assembly
r. B sample testing
s. Hardware module testing
t. Integration testing

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Design & Development support for 2/3 kW Single Phase EV charger
u. System testing
v. Share system test result with Selec
w. B sample samples dispatch to Selec

4. Assumptions:
1. Selec will revert within 2 working days for any query, inputs required and confirmation
2. Selec will provide all necessary document in English (i.e. specification document, query reply, controls design
document, feasibility phase documents etc.)
3. Success factors limits are not defined and will be evolved during concept phase
4. All tests will be performed at room temperature. LTTS and Selec will agree on tests to be done at temperature
extremes.
5. Selec to share list of test case for system testing & unit testing apart from the STP that LTTS will share.
6. Selec will provide necessary format of deliverables else LTTS will use LTTS format.
7. Acceptance criteria for test results shall be defined as part of prototype requirement
8. LTTS will provide budgetary quote for proposal.
9. LTTS will be free to do internal placement and modification of mechanical design meeting system requirement
10. LTTS will submit separate proposal for onsite additional visit or support.
11. LTTS will try to create up to three ideas and concept
12. Selec will get part cost for bulk quantity for product cost decision
13. LTTS will provide all possible evidence to compare cost [relative cost - based on size, shape material, complexity,
manufacturability etc..] of each option to take cost decision
14. LTTS will submit two Barrack POC sample to Selec
15. Barrack POC is to check functionality of 2/3kW single phase EV charger section, thermal or EMI EMC will not be
considered in design
16. LTTS will test prototype samples and B samples with available DC supply and resistive/electronic load. LTTS will
use the Selec’s test facility for some of the test cases if required.
17. - Selec will be responsible for PCB, components (electrical and mechanical) procurement and PCB assembly.
18. LTTS will resubmit the proposal for B sample.
19. Delivery schedule is considering review time and input or query clarification by Selec within 3 working days. If
customer takes more than specified time, LTTS will estimate schedule and cost impact and communicate to client.
20. No redundant Power supplies to be considered in design
21. Selec will send the documentation or details, if any specific requirement to be fulfilled w.r.t. software
implementation apart from provided in current requirement specification document (Attached in the “Input
received” section)
22. Software architecture and design will be defined by LTTS
23. LTTS is not planning to use any OS (operating system) for firmware development.
24. Enclosure Parts will be made by Aluminium (Casting / Machining process).
25. EMI/EMC testing (Apart from the testing mentioned in the point 3 of “Exclusion” section) is not considered in the
current scope
26. The charger should work continuously at full load and +55°C ambient temperature.
27. There is no power derating of the charger wrt the ambient temperature
28. Enclosure size should be same for both the charger variants (2kW (natural cooled) and 3kW (Forced (Fan) cooled))
29. Selec will support in mechanical Design, component procurement, proto assembly and will work concurrently for
product development.
30. Any mechanical tests (shock & vibration, IP etc.) are not considered in scope. LTTS and Selec will discuss for any
specific requirement.
31. Design life will be considered at component level for electrolytic component only
32. LTTS will need 2-4 weeks for team building and project initiation after PO received
33. Product expected cost will not be part of the current scope upto A sample design, LTTS will do the product cost
analyze activity after the A sample delivery. Selec will share the approved vendor list for the product costing
activity.

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Design & Development support for 2/3 kW Single Phase EV charger
5. Draft Deliverables and acceptance criteria(LTTS will update after getting
confirmation of DOU from Selec)
A-phase design
Deliverables
Sr.
Deliverables Deliverable content Acceptance criteria Template
No.
Format
1 System
Capture requirements on HW, SW Review and confirm
Requirement MS Word or MS
1.1. Mech., Thermal from Selec specifications w.r.t system
specification excel,
specification document specification
Test cases from requirement
System test plan & HW
1.2. specification as required for system Review and approval MS excel
unit test plan
testing & hardware design
Concept report (will be Up to 3 concepts for fitment and
1.3. Review and approval 3D model, PPT
done with Selec) integration
HW
2 [Barrack POC, POC, B
sample]
Component list
2.1. BOM Selec review and approval BOM in MS Excel,

1. Schematic file of each boards

2.2. Schematic 2. Board to board interface Selec review and approval Pdf or MS Excel
diagram
Design calculation of
-All power components for ACF, PFC,
DC DC convertor, DCF
2.3. Design calculations -Derating calculations Selec review and approval Excel
-Efficiency calculations
-Temperature rise calculations for
major power components
SW file, Pdf or
2.4. Software design Design document and Actual SW Selec review and approval
MS Excel
ACF choke, PFC boost inductor, DC DC
Magnetic components
2.5. convertor transformer, DCF inductor Selec review and approval Excel
specification
design specifications
PFC circuit simulation results - ripple
Circuit simulation voltage, current, stability
2.6. Selec review and approval Excel
results DC DC circuit simulation results - ripple
voltage, current, stability
HW and SW interface
2.7. - Selec review and approval Excel
document

2.8. PCB Design PCB design file Selec review and approval Gerber file

CFD deliverables [In

3
case required]
Thermal simulation 1. CFD simulation on Selec provided
results on concept concept 3D assembly with LTTS
3.1. Selec review and approval ppt / Excel
model for both the estimated worst case power losses
model (2kW and 3kW) 2. Result report
Thermal simulation 1. CFD simulation on iteration on
3.2. Selec review and approval ppt / Excel
results on concept cooling mechanism on Selec

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Design & Development support for 2/3 kW Single Phase EV charger
model- Iteration1 for provided concept 3D model and
both the model (2kW LTTS estimated power losses
and 3kW)
Thermal simulation 1. Detail thermal simulation on two
results on detail design patterns on latest mechanical
3.3. Selec review and approval ppt / Excel
for both the model assembly including latest PCBAs
(2kW and 3kW) 2. Result report
Thermal simulation 1. Idea generation and design
results on detail design changes to recover NG results
3.4. Selec review and approval ppt / Excel
for both the model 2. Iteration1 with changes on cooling
(2kW and 3kW) structure to improve NG results
Mechanical
4 deliverables
[POC, B sample]
Mechanical 3D Mechanical 3D assembly (containing Solid works files
4.1 Selec review and approval
assembly PCB assemblies & STEP file
Mechanical 2D 2D drawings for all mechanical parts Pdf file / solid
4.2 Selec review and approval
drawings and assembly works drawings
Tolerance stack-up Tolerance stack-up & Gap analysis
4.3 Selec review and approval Excel & PPT
analysis report

Deliverable of Testing phase:

Sr. Deliverables
Deliverables Deliverable content Acceptance criteria
No. Template Format
1 Barrack POC
1. Test report capturing following test
results on one sample:
2. Output voltage regulation tests
(steady state, transient)
System functional test 3. Charger output ripple tests Selec review and
1.1 Excel
results on Barrack POC 4. Efficiency tests approval
5. Power factor
6. Protection tests (Input & Output
undervoltage and overvoltage, Short
circuit, Over temperature)
1. Physical POC prototype samples (02 Sample with limited
Functional Barrack POC nos.) functions
1.2 Samples
prototypes 2. Checklist for basic functionality, Selec review and
Inspection report approval
2 POC
Test report capturing following test
results on one sample:
1. Output voltage regulation tests
(steady state, transient)
2. Charger output ripple tests
System functional test Selec review and
2.1 3. Efficiency tests Excel
results on POC approval
4. Power factor
5. Protection tests (Input & Output
undervoltage and overvoltage,
Short circuit, Over temperature)
6. Safety (Megger, HV tests)

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Design & Development support for 2/3 kW Single Phase EV charger
7. Continuous operation tests at
worst case ambient (+55C
ambient)
3. Physical POC prototype samples (02 Sample with limited
Functional POC nos.) functions
2.2 Samples
prototypes 4. Checklist for basic functionality, Selec review and
Inspection report approval
3 B sample
Test report capturing following test
results on one sample:
1. Output voltage regulation tests
(steady state, transient)
2. Charger output ripple tests
3. Efficiency tests
System functional test 4. Power factor Selec review and
3.1 Excel
results on B sample 5. Protection tests (Input & Output approval
undervoltage and overvoltage,
Short circuit, Over temperature)
6. Safety (Megger, HV tests)
7. Continuous operation tests at
worst case ambient (+55C
ambient)
5. Physical B sample prototype samples Sample with limited
Functional B sample (02 nos.) functions
3.2 Samples
prototypes 6. Checked for basic functionality, Selec review and
Inspection report approval

6. Milestone and Delivery Schedule:

Milestone, Delivery Schedule and Commercial details will be submitted to Selec at the time of proposal, post DOU

discussion.

7. Exclusions:
1. Cost for bulk production costing
2. Patent search/Infringement analysis/Market study
3. EMI and EMC testing and certification. LTTS can perform only pre-compliance for conducted including CE, SURGE,
EFT, ESD. For all other test LTTS will work with external lab/Selec lab based on the mutual agreement.
4. Development of Mechanical prototype in Barrack POC
5. Tooling and Production support
6. Design & Development of Standard parts such as connectors, Inlet and Outlet Nozzles etc.
7. Pre-compliance or certification testing
8. Production Support
9. Service and User Manual Preparation
10. Design & Manufacturing of Test benches and fixtures for production
11. Electro-magnetic simulation for magnetics parts
12.
13. Shock and Vibration testing
14. Other than mentioned in Scope and understanding
15. Lab testing of parts for ROHS / REACH compliance
16. Charger to Vehicle communications

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Design & Development support for 2/3 kW Single Phase EV charger
17. Charger to grid communication.
18. Packaging & Labelling Design
19. Field Trail, Field Support, Maintenance, etc.
20. Reliability calculations and analysis
21. Documentation other than mentioned deliverables
22. Design and development of HMI or PC utility
23.

8. Inputs Received/Required:
Below Is the requirement received from Selec.

Spec draft_EV
Charger_2_3KW_V1.doc

Inputs required:

1. Initial CAD start file if available

2. Derating guidelines if any
3. SW requirement specification document
4. Pollution degree and Overvoltage category specification
5. Tentative Dimensions of the chargers
6. Document templates if any
7. Standards for mechanical design if any
8. Specifications, Testing & Validation standards
9. CAN Diagnostics functionality details
10. PC utility for CAN testing and CAN converter hardware
11. Approved vendor list if any
12. Manufacturing guidelines, templates for mechanical models and drawings
13. EMI EMC standard for design

Queries:

1. What all parameters need to be send over CAN communication?

2. LTTS considered local vendors (LTTS approved vendors) for prototype & Alpha/Beta unit material. Please confirm.
3. Please confirm if there are reusable design modules from past project, LTTS will estimate accordingly.
4. LTTS want to know the thought for considering the large variation of the input AC supply frequency (47-63Hz)

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Design & Development support for 2/3 kW Single Phase EV charger
9. Risks & Mitigation:
Risk
Priority
Sl. No. Risk Description (High Impact Mitigation
/Medium/
Low)
Lead Time for Procurement The implications on schedule Try and pre-order the critical, long
of Components / items and the resultant idling of lead components / items with
1 High
impacting schedules and resources will be discussed continuous follow up with vendor.
resource idling with the Selec
Change in Functional
Specifications resulting Any new / incremental Consider all possible functional
2 incremental design High requirements shall follow requirements before the
iterations impacting change request process implementation phase.
timelines and cost
If approval / clarification is Selec shall identify alternate stake
Delay in providing review
not provided within holders and approve the
approvals or input / query
stipulated period, it will be deliverables on time (in the
3 clarifications from Selec Medium
deemed as approved or absence of primary stake holders).
impacting the next
resultant idling will be
milestone deliverables
charged to Selec.
Delays resulting due to
logistic issues (shipment,
Delay in receipt of physical Selec shall share the pro forma
customs etc.) will have
shipments by LTTS causing invoice of the shipment for
schedule implication and
slippages of the planned verification by LTTS before the
4 Medium will be treated accepted.
deliverables impacting actual shipment to reduce delays in
overall project timelines Resource idling resulting due the custom clearance.
and cost to delay in actual shipment
from the Selec will be
charged.
Selec dependencies on
prototype fabrication (ex:
approvals), integrated LTTS would highlight these
The implications on schedule
system testing (Ex: dependencies in the appropriate
5 Medium and the resultant cost will be
Hardware, chassis, weekly status calls for timely action
discussed with Selec.
customer arranged stacks from Selec.
etc.) causing schedule
slippages and idling cost
Integration of defective
third-party modules / tools The implications on schedule
/ bought out / customer will be discussed with Selec.
supplied items or project Any additional efforts Refer section of Concessional
6 Medium
artifacts, demanding towards co-ordination with Acceptance
additional efforts / vendors, design / testing will
timelines in achieving the be charged to Selec
functionalities

Delay in finalizing Schedules and effort estimates will

7 comprehensive user Medium Cost and schedule be revised in consultation with
requirements Selec.

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Design & Development support for 2/3 kW Single Phase EV charger
Risk
Priority
Sl. No. Risk Description (High Impact Mitigation
/Medium/
Low)
LTTS would share the templates
Change of template or before project kick-off and other
8 deliverable format and Medium Cost and schedule documentation format and needs
other documentation to approve within 3 working days to
avoid any schedule delay
There may be delay in
finalization of electro- Follow-up with vendors to get
magnetic component information in time.
9 Medium Schedule
specification due to delay
Intimate regularly to Selec on this
due to external vendor
communication
communication

Selec to get necessary approval

Major design rework and from BMW on manufacturability
10 Manufacturability High
delay in B sample aspect

Delay in Deliverables due to LTTS have the capability to enable

11 COVID-19 virus outbreak Low Schedule WFH if situation required and LTTS
will continuously inform Selec as it
progresses

Design change requirement

due to component LTTS will try to order the
12 unavailability or out of High Schedule and Cost components section wise.
stock situation at the time
of procurement

10. Development Tools

Sl. No Activity Tools
1 Schematic Altium/ORCAD/PADS
2 Circuit simulation PSIM/LTSPICE
3 Thermal Simulation ANSYS/ ICEPAK
4 Design documents MS OFFICE
5 Mechanical Solidworks/ Autodesk Inventor
6 PCB PADS/ORCAD

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