china infineon symposium september, 2010€¦ · patrick leteinturier, senior principal powertrain...
TRANSCRIPT
Patrick Leteinturier,
Senior Principal Powertrain Systems
HEV & EV system solutionsChina Infineon Symposium
September, 2010
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 2
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 3
Electric Traction Vehicle Growth Trend
2020
Trends
• Highly pushed by market demands and government incentives
• Success heavily depends on fuel prices and battery costs
• Up to 7% of the light vehicle production by 2016 and 15% by 2020 (Moderate)
• Require a fast change at all levels- Driving habits- Supplier Chain- Infrastructure- Car service- …
Production of Electric Vehicles by Type
Millions of Units
0,6 1,0 1,2 1,4 1,8 2,1 2,7 4,0
5,8 7,3
2,4
1,1
0,8 0,5
1,7
2,3
1,5
0,4 0,7
1,1
-
2,0
4,0
6,0
8,0
10,0
12,0
14,0
2008 2009 2010 2011 2012 2013 2014 2016 2018 2020
EVs
PHEVs
HEVs
Production of Electric Vehicles
Millions of Units
-
5,0
10,0
15,0
20,0
25,0
30,0
2008 2014 2020
Baseline
Moderate
Optimistic
Source: IMS Research, Nov-09
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 4
CO2 Efficiency
• What is the reference use case? • Use a standard NEDC / FTP
• Use an other reference that the emission
cycle
• What is included?• Accessories: water, fuel, oil pump
• HVAC (Heat, Ventilation, Air Cond.)
• Power steering, Braking, ESP
• Infotainment
• Lighting …
• Monitoring CO2 over lifetime?• Continuous assessment of the
performance of the plan
• Switch the MIL in case of performance
degradation more than allowed
What to compare?
820s 1220s
40
60
80
100
120
km/h
20
80
100
120
40
60
80
100
120
20
Urban
"ECE"
extra-urban
"EUDC"
A < 60
B 60 to 95
E 130 to 160
C 95 to 110
D 110 to 130
F 160 to 200
G > 200
gCO2/km
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 5
Power and Energy consumption
• Hypothesis
• Mass 1,5 tone Vehicle
• Rolling 8 kWh / 100km
• Aerodynamic
07 kWh / 100km at 100 km/h
12 kWh / 100km at 130 km/h
• Accel 0 to 100km/h in 10s
• Brake 100km/h to 0 in 50m
• Results
• 15 kWh/100km at 100km/h
• 20 kWh/100km at 130km/h• ------------------------------------------------------------------------------------------------
• 80 kW to Accel (0 to 100km/h in 10s)
• 15 kW at 100km/h (Steady Speed)
• 26 kW at 130km/h (Steady Speed)
• 300 kW to Brake (100km/h to 0 in 50m)
Power and Energy
Mass
Rolling
Aerodynamic
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 6
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 7
Parallel Hybrid
Transmission
20 kW
Inverter
HV Bat. DC/DCBat.Mgn
12V board netLV Bat.
2 kWh
DC/DC
Motor
Engine
The vehicle electrification: a wide range of architectures
Parallel Hybrid - Dual Clutch
20 kWTra
nsm
issio
n
Inverter
HV Bat. DC/DCBat.Mgn
12V board netLV Bat.
2 kWh
DC/DC
Motor
Engine Serial Hybrid
Trans.
12V board net
LV Bat.
30 kW 50 kW
2 kWh
Engine
Motor
Bat.Mgn
Gene
Inv-1 Inv-2
DC/DC
HV Bat. Serial - Parallel Hybrid
Trans.
12V board net
LV Bat.
30 kW 50 kW
2 kWh
Engine
Motor
Bat.Mgn
Gene
Inv-1 Inv-2
DC/DC
HV Bat. Power Split Hybrid
Trans.
1,3 kWh
Engine
30 kW
50 kW
HV Bat. DC/DC12V board net
LV Bat. DC/DCBat.Mgn
Motor
Generator
Inverter
Inverter
Two Mode Hybrid
2 kWh
30 kWHV Bat. DC/DC12V board net
LV Bat. DC/DCBat.Mgn
Inver.
T
Engine
Mot1
Inver.
Mot2
55-100 kW 55-100 kW
Axial split Hybrid
Transmission
Trans.
2 kWh
Moto
r
Inv.Bat.Mgn
HV Bat.
27 kW
12V board net
En
gin
e LV Bat.
Invert
er
Sta
rter-
Genera
tor
• Functions
• Start - Stop
• Regenerative braking
• Torque boost
• Low / part speed electric drive
• Challenges
• Engine temperature control
• Emissions at Start & Stop
• Control of transient
• Safety critical X-by-wire
• Vehicle stability -> ESP
• High voltage
• Need of cabin heating
• Need of cabin cooling
• …
Functions
Challenges
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 8
PHEV, EREV and EV
Trans.
HV Bat. Bat.Mgn
ChargerAC/DC
Infra-structure
12V board net
DC/DC LV Bat.
Gene
Inv-1
range extender20 kW 50 kW
12 kWh
3 to 10 kW
Motor/Gene.
Trans.HV Bat. Bat.Mgn In
v.
ChargerAC/DC
Infra-structure
12V board net
DC/DC LV Bat.
HVAccessories
DC/D
C
50 kW25 kWh
3, 10, 30 kW
• Function• Drive 100 km Electric
• Solutions• 1) Range extender for insurance in case
the battery is getting empty. Then no
need of good efficiency. The cost, the
mass and the volume should be small.
• 2) Range extender for long distance
cruising requires a good efficiency and
emission control.
• Function• Drive 200 km Electric
• Solutions• Charging can vary between 3, 10, 30 kW
• The possibility to quickly replace the
battery at the service station
• Challenges• Infrastructure, Grid, Charger, Standard …
• Battery (cost, power density, life time)…
Engine
1
2
1 PHEV and EREV
2 EV Electric Vehicle
HVAccessories
Motor
Inv-2
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 9
E-Mobility -> total new vehicle architecture
ChargerAC/DC
Infra-structure
DC/DC
LV Bat.
HVAccessories
DC/D
C
Inv.
HV Bat. Bat.Mgn
Trans.
Moto
r/G
ene.
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 10
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 11
Electric drive and control Compact and Easy for Motor Management
Motor management replacing Engine management system (EMS)
Large varieties of power: up to 80kW
Large varieties of motor types: synchronous, asynchronous, reluctance
Modules enable compact design
Control IC with integratedinsulation
A
A
B
B C
C N
S
0
V+
A+ B+ C+
B
A
C
A0 B0 C0 Ia
IcIb
Va
VcVb
V1 V2
Motor Position
Motor Temperature
Motor Voltages & Currents
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 12
Power module, integrated solution
Family of inverters up to 80 kW
Switch up to 800A/650V IGBT3 dies
Pinfin copper base plate for direct water cooling
High converter efficiency due to low power losses
Cost efficient system approach
High reliability, and life time
Automotive qualified & quality
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 13
Ultimate silicon technologies: IGBT, SiC, JFet
Advanced IGBT roadmap
Trench and field stop
Ultra thin wafer
Large variation of voltage classes: 400, 600, 650, 700, 1200 Volts
Very temperature capability:150°, 175°, 200° C
Diagnosis & Current sense technology
Ready SiC diodes, Future JFet
100
200
300
400
500
0 1 2 3 4 5
Cu
rren
t (A
)
Voltage (V)
Si-MOSFET
Potential of the CoolMOSTechnology
SiCxFET
Si- IGBT(low loss)
SiC IGBT
Design criteria for system cost
Design criteria for efficiency
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 14
Gate driver integrates isolation by on-chip coreless transformer technology
Microsystem ensures isolation by integrated transformers and eliminates need for a core to direct the magnetic flux
1ED020I12-FA / 1ED020I12FTA
Peak output current (+/- 2 A)
Threshold Detection (9 V)
Automotive qualified
SO-20 package (wide)
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 15
Mapping to componentsIFX possible product offering
IGBTHS
P & T°Receive
MotorPosition
MotorTemperature
V, I, T°Signal Acqui.,Cond. & Trans.
Low Voltage High Voltage
A
A
B
B C
C N
S
Dri
ver
Ctr
IGBTLS
PS + Safing log.Guardian
Tra
nsceiv
er
Sense
Control Board Driver Board Power Module
µC
Checker
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 16
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 17
Battery Management (Li-ion)
Battery power On/Off Battery emergency stop Battery charging / discharging Battery state of charge Battery state of health Battery active load balancing Battery T° monitoring High impedance in Off mode Leakage detection
Lo
ad
ba
lan
ce
Battery
Mangement
0
200
400
600
800
1000
1200
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Euro/kWh
25kWh Battery
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 18
Plant Protection
• Objectives• Switch the system on and off
• Insulate the system
• Over current protection
• Over voltage protection
• Over temperature protection
• Power range• 20 to 100 kW
• 200 to 1200 V
• Solutions• Use the inverter with IGBTs
• Use relays
• Use fuses
• Challenges• Detection and Reaction time
• High Voltage and high current
• The Captive and Inductive load
Turn on & off
A
A
B
B C
C N
S
Battery
Sw
itch
DC lin
k
Inverter Motor
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 19
Main switch needs more than relays
• Objective• Reduce the function cost by using an
inexpensive relay
• Provide diagnosis capability
• Limit the current at turn on
• Robust turn off
• Off mode• All Relays off , Impedance > 500 kOhm
• Turn On• Turn on Twin Relay, Turn on the IGBT 1
• Limit the current with the PTC
• Turn on the S-Relay, Turn off the IGBT 1
• On mode• All Relays on, Impedance ≈ mOhm
• Turn Off• Turn on the IGBT 2, Turn off the S-Relay
• Turn off the IGBT 2, Turn off Twin Relay
Smart Safe Switch
PTC1 J201
Control
from
µC
Rel 1
Vbatt – 10V
Power Out
(Motor)
Power In
(Battery)
Q1
IGP50N60T
S1
TLE4906
Hall Switch
OC1
1 2
Sequence
Control
Circuit
Q2
IKW75
N60
3
4
Fuse
Tw
in r
ela
y
Load
Batt
ery
S-Relay
S-Relay
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 20
• Features• One Li-ion battery cell has nom. Voltage
between 3.2V and 3.8V
• Each cell voltage depends on the state of
charge.
• Overcharge, Undercharge, OverT° and
UnderT° will damage the cell
• 10 to 12 cells in serial are assembled to
build a battery pack
• For example 10 packs are in serial to
build a 400V battery
• Objectives• Optimize the battery life time
• Optimize the battery capacity
• Perform the state of health
• Perform the state of charge
• Balance the charge over the cell
• Compensate manufacturing difference
• Compensate aging difference
• Monitor the battery temperature
• Perform active cooling (air or liquid)
Li-ion Battery
Battery management Efficiency –Extended battery life time and driving range
Overcharge
Undercharge
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 21
Discharging of older 2.3Ah A123 cells with 1.8Aupper: no Balancing lower: active Balancing
Upper: 46min / Lower: 54 min Benefit: 17.3%
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
time [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
2,00
2,10
2,20
2,30
2,40
2,50
2,60
2,70
2,80
2,90
3,00
3,10
3,20
3,30
3,40
3,50
3,60
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
time [min]
U0
U1
U2
U3
U4
U5
U6
U7
U8
U9
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 22
Battery Management Partitioning –cost efficient solution to address lifetime and safety requirements
Infineon has developed CSC “Cell Supervision Circuit” doing activecell balancing and monitoring.
The active cell balancing system is especially well suited for high performance batteries e.g.Electric Vehicle and P-HEV
CSC allows to use 15% more battery capacity compared to passive balancing
CSC performs Top Balancing, Bottom Balancing and Inter-Block Balancing
CSC balances up to 12 cellsOne CSC is used per blockA battery has 10 – 20 Blocks
CSC supports ASIL requirements
CSC: Cell Supervision Circuit
Block -
Block +
S2
SP1
Stack +
Stack -
SP2
Block -
Block +
S3
SP1
SP2
TOP Balancing Inter Block
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 23
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 24
On-board battery charging – Efficiency and high-power density for small form factor
Classes 3kW, 10kW, 30kW, (43kW) Single phase and 3 phases Combine 3 classes into one module Preferred on board charger Recognition of the devices Safe connection and disconnection Recognition the plug connection Diag of current flow: Ground – Earth Highly efficient rectification with SiC
diodes Reference designs for easy use
Rect
Driver Logic
Diagnosis/MonitoringAuthentication/Billing
PowernetComm
CarComm
AC/DC
L1
L2
L3
N
HV+
HV-Filter PFC DC/DC
CANH
CANL
DC/DC 12V/100W
KL15
KL30
KL31
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 25
Different topologies are possible –Charger is a non differentiating product
o Input:
Input current: 16A per phase
Input voltage: either 110V or 230V, 50Hz-60Hz
3kW-11kW
o Output:
3kW – 11kW
250V – 450V
o Mechanical constraints
3kW converter -> 3l, 5kg
20kW converter -> <8l, 12kg
Water or aircooling, sealed housing, IP67
o Efficiency: >94%
o Power Factor: 0,98@120V,0,99@230V
Bridgerectifier
PFC stage
DCDC converter
ubattery
n : 1
uAC
ihighi1
i2
D11S11
D21S21
iL1
iClow
iChigh
D12S12
D22S22
D13S13
D23S23
L2
L3ilow
uhigh Chigh
ulow
iL2
iL3
Clow
L1
K
Multi-Phase 2-Quadrant Converter without galvanic Insulation
DC/DC withZero voltage switching
Example of charger
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 26
Electro shock Consequences
Injury influencing factors
Current type (AC frequency or DC)
Current intensity
Current Path
Duration
Body resistance
Voltage
Human body resistance varies
Contact area
Contact pressure
Thickness of the skin
Presence of moisture
Weight, size, fatigue ...
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 27
Communication to infrastructure –Ensures mobility
Communication from car to grid and to the charging / billing management systems
ICs / chip sets / reference designs
for grid communication via powerline
for GPS and wireless communication for charging management
for authentication with security chips
GPS
RF
Baseband
Source: E.ON Energie
Source: GoGreenSolar.com
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 28
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 29Page 29
E-Mobility ArchitectureImplementation of Safety and Diagnosis
E-Mobility is an X-by-Wire system that requires the most stringent safety integrity care ISO 26262 is classifying application according to Severity, Exposure, Controllability Most sub applications (inverter, battery management, DC/DC HV-LV) are ASIL-D
HV-LVDC/DC
LVBat
ChargerAC/DC
HV Accessories
HPDC/DC
Inv.
ASIL-D
ASIL-D
ASIL-D
ASIL-C
QM
HVBat
Bat.Mgmt.E
-Moto
r
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 30Page 30
Safety integrity level
IEC 61508
ISO 26262
Durability
Availability
Reliability
Cost
Severity
Exposure
Controllability
Safety compliance
Tricore based ASILDsafety core available
µC solutions
Redundant
Diverse
I/O checker
Gate Drivers
Diagnostics
Dead time ctr.
Emergency stop
IGBT, Diodes
Sensors
Current, Voltage
Position, T°
Power supply
Safing log.
Monitoring
DependabilityArchitecture
Solutions
Dependable
Power
Dependable
Communication
& interconnect
Dependable
actuation
Dependable
Computation
Dependable
sensing
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 31
Presentation Outline
HEV and EV market trends
HEV & EV architectures
Motor drive
Battery Management
DC/DC and Charger
Safety Integrity
Summary / Concluding remarks
Copyright © Infineon Technologies 2010. All rights reserved.06.09.2010 Page 32
Summary
Thank you!
The race for CO2 efficiency and environment friendly
vehicle is driving Powertrain toward electrification.
Electric vehicle is a disruptive technology.
New actors on the stage: Established players have to
re-define their competencies.
We have to proactively create the shift towards
e-mobility cooperating along the value chain.
Infineon is committed to support the industry in China
with leading edge products and technologies, delivering
cost effectiveness, high efficiency and power density