Delphi Helps Vehicle Makers Turn Out High-Tech Hybrids

Delphi Integrates Hybrid Systems to Help OEMs Increase Efficiency and Consumer Value

DETROIT, Oct. 16 // -- Delphi Corp. has been selected by Ford Motor Company to provide hybrid electrical powertrain systems technologies for two Ford hybrid vehicle platforms, company officials announced here today at the 2006 Convergence Conference.

Delphi will provide the battery pack systems and cooling systems for the 2008 Ford Fusion Hybrid and Mercury Milan Hybrid vehicles. It will also provide hybrid vehicle electronics for several other yet-to-be announced vehicle customers.

Delphi delivers significant value to hybrid vehicle auto manufacturers by bringing the right electronic and electrical powertrain component systems, thermal management components and wiring architecture for their hybrid vehicles.

Leveraging its breadth and depth of systems integration and power electronics expertise, Delphi's power electronics operation provides advanced technology systems to produce hybrid vehicle powertrains that are industry leaders in efficiency.

"Delphi has been developing power electronics and technologies for nearly 20 years," said Thomas Goesch, Delphi product line manager. "We are using our unique systems integration 'know how' in this emerging field to help hybrid vehicle manufacturers offer consumers efficient, cost competitive and reliable hybrid vehicles."

To complement the power electronics, Delphi offers shielded electrical harnesses solutions for connecting the hybrid electric vehicle system. Custom connection systems, addressing safety, sealing, and shielding are an integral part of the wiring package. The overall wiring systems costs are reduced through bundled shielding products.

Addressing the thermal management challenges of hybrid powertrains can potentially have a significant impact on hybrid vehicle climate systems. Delphi's core thermal systems technologies can satisfy the need to cool batteries and power electronics without compromising passenger comfort. Delphi's systems approach will ensure that the total energy required to manage the thermal needs of the hybrid powertrain and provide passenger comfort result in the best overall value, including good fuel economy and uncompromised comfort.

Delphi has had more than 70 patents issued since 2000 in power electronics and advanced energy systems. During the mid-1990s, Delphi built much of the electronics, including the hybrid module and electrical systems, for the first electric vehicles built and made available on the market by a major manufacturer in North America.

As oil prices continue to rise, Delphi's power electronics experience is gaining more traction with vehicle manufacturers. More hybrid vehicles are hitting the road in North America that combine the features of two energy sources -- usually gasoline and electricity -- to help drivers save money on the cost of operating a vehicle. Currently, buyers of hybrid vehicles in the United States are eligible for tax advantages and in some states insurance reductions. In addition, hybrid vehicles emit fewer emissions than gasoline- only powered vehicles.

"Starting early in the development process with vehicle manufacturers, Delphi focuses on aggressively lowering the hybrid electric vehicle cost of powertrain electrification through component design, system design, manufacturability and controls and algorithms development," Goesch said. "These savings can be passed on to add more value for the consumer."

Delphi's advanced electronics allow the electric motor to act not only as a motor but also a generator that can draw energy from the batteries to accelerate the vehicle. In addition, the same electronics allow the motor to slow the vehicle down and return a recharge to the batteries.

Delphi has created an extensive power electronics development lab with advanced analysis and design tools to complement its manufacturing operations. Delphi's capabilities include development from silicon to electronic modules and "art to part" prototyping.

Delphi creates custom designs and builds lower-cost power electronics that include DC/DC converters, ECM/HEV controllers, inverters and high-voltage battery packs with an optional 120/240VAC mobile power unit that integrate seamlessly into the vehicle's electrical architecture. Delphi's power electronics portfolio includes:

DC/DC (Direct Current to Direct Current) Converters

This product changes high-voltage battery power to lower voltages to operate traditional 12-volt accessories and lighting, as well as vehicle systems such as air conditioning, brake assist, and power steering.

ECM/HEV Controllers (Engine Control Module/Hybrid Electric Vehicle
Electronic Controller)

This product provides supervisory control of the vehicle's engine, transmission, and hybrid drive motor/generators to provide peak vehicle performance, emissions, and economy.


Inverters provide phased AC (Alternating Current) power for vehicle traction motors and generators, as well as auxiliary pumps and drives.

High Voltage Battery Pack

The battery pack stores energy for use in launching and accelerating the vehicle.

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Source: Delphi Corporation

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