the application of sic on vehicles and its future
TRANSCRIPT
1
The application of SiC on vehicles
and its future
4th July, 2018
Dr. Kimimori Hamada
Project General Manager
EHV Electronics Design Div.
Toyota Motor Corporation
Center for Power Electronics Annual Conference 2018Loughborough University
2Contents
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
3What our customers and society require for cars
4To reduce CO2 emissions・・・
5Global Population Growth and Vehicle Units in Operation
Sources: 1) United Nations Department of Economic and Social Affairs2) World Business Council for Sustainable Development
10
5
0
(in billions)
1950 2000 2050 2100
Asia
Africa
North America
Europe
Un
its in
op
era
tion
(in
billion
s)
0
1
Units in operation
Population
1 vehicle per 40 people
750 mil. units
1 vehicle per 8 people
Population
Population and number of vehicles on load will grow mainly in emerging markets
70 mil.units
Latin America, Caribbean
Oceania
6
1) Improving fuel efficiency
To address 3 issues,vehicle electrification is essential
3) Making emissions cleaner to prevent air pollution
Environment-friendly vehicles contribute to the environment only when widely used.
Toyota’s Basic Response
2) Reducing CO2 to prevent global warming
7
Toyota’s development of electrified vehicles
Contents
8
FCV
Passenger cars
Route buses
Travel distance
Home deliveryvehicles
HV/PHV
Short-distance commuter vehicles
Personal mobility
Full-size trucks
Home delivery trucks
EV
EVs: Short-to-medium distance; HVs & PHVs: Wide-use; FCVs: Medium-to-long distance
Environmentally friendly electrified vehiclesV
eh
icle
siz
e
9
2020 20502010
EV
PHV
FCVEV
Challenge 1: New-vehicle Zero CO2 Emissions Challenge
2010 2050
Average CO2
emissions for new vehicles
90% reduction
HV
Accelerate next-generation vehicle development
toward 90% reduction in CO2 emissions
New Vehicle Zero CO2 Emissions Challenge
Vehicles poweredby only internal
combustion engines
10Vehicle electrification milestones
1990 20502010 204020202000 2030
2050: Zero CO2emissions challenge
1997: World’s firstmass-production HEV
2030
Electrified vehicles > 50%
BEV・FCEV >10%
By around 2025:Electrified gradeavailable for allvehicle models
PHEVs
HEVs
FCEVs
BEVs
From 2020:BEV rolloutin earnest
2014: FCEV
Vehicles poweredby only internal
combustion engines
11
0
20
40
60
80
100
120
140
160
180
200
0
100
200
300
400
500
600
700
800
900
1,000
1,100
1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017
販売台数
(年間)
販売台数
(累計)
累計(万台) 年間(万台)
100万台
300万台
500万台
(1月)0
200
400
600
800
1,000
1,200
1,400
1,600
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
CO2削減量
(年間)
CO2削減量
(累計)
累計(万t) 年間(万t)
0
100
200
300
400
500
600
700
800
900
1,000
1,100
1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017
0
200
400
600
800
1,000
1,200
1,400
1,600
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
77 mil. tons
9 mil.
0
20
40
60
80
100
120
140
160
180
200
No. of units sold (annual)
No. of units sold (total)
CO2 reduction (annual)
CO2 reduction (total)
0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0 Yearly(in millions of units)
0
2
4
6
8
10
12
14
16
Yearly(in millions of tons)
10 million
Toyota HV Sales Results & CO2 Reduction
5 mil.
3 mil.
1 mil.
Total HV sales reached 10 million units in January 2017!CO2 reduction compared to similar gasoline-engine vehicles was 77 mil. tons.
11
10
9
8
7
6
5
4
3
2
1
0
0
10
20
30
40
50
60
70
80
Total(in millions of units)
Total(in millions of tons)
Total sales11.09 mil., units(at end of Sept. 2017)
12
GlobalTotal
Toyota
(Unit: 1,000 vehicles)Calculated by Toyota from IHS data
HV2,410
HV+PHV+FCV1,400
EV490
PHV330
FCV2.6
43%Electrified VehicleMarket Share (CY 2016)
3,232
Top OEM of Electrified Vehicles
13
Toyota’s vehicle electrification technologies
Contents
14
Motor
Battery
PCU(Inverter)
Charging
EV
Engine Charging
PHV
Engine
HV
Fuel Cell HydrogenTank
FCVH2
O2
H2
3 Core Technologies and Electrified Vehicles
15
Motor
PCU
Battery
Output:200%
Volume:50%
Weight:30~50%
Energy loss:80%
Volume:60%
Volume:50%
UP DOWN
DOWN
DOWN
DOWN
DOWN
Power Density400%
UP
Evolution of 3 Core Technologies
16
燃費(km/L)
HVシステムコスト
10-15 Japanese test cycle
JC08 Japanese test cycle
HV system cost
Fuel efficiency (km/L)
First-generation PriusSecond-generation Prius Third-generation Prius New Prius
HV technology significantly evolved in fuel efficiency with reduced
cost
燃費(km/L)
HVシステムコスト
10-15 Japanese test cycle
JC08 Japanese test cycle
HV system cost
Fuel efficiency (km/L)
1st-generation Prius 2nd-generation Prius 3rd-generation Prius New Prius
HV technology significantly evolved in terms of fuel efficiency
with reduced cost
Higher Fuel Efficiency & Lower Hybrid System Costs
17
Application of SiC Power Semiconductor Devices on Electrified Vehicles
Contents
18CAMRY
Full SiC PCU
SiC MOSFET SiC JBS Diode
・Installing SiC power semiconductors (MOSs and diodes) in the PCU・We started road testing of this Camry in early February, 2015・Evaluating fuel efficiency under various driving condition
19Fuel cell system of the FC bus
FC Boost Converter FC Stack
FC boostConverterSiC JBS Diode
20Tokyo Toei FC Bus
・Regular commercial operation in Tokyo since March, 2017
・Over 100 FC Buses will be introduced before Tokyo Olympic/Paralympic games
To(都)05line: Tokyo station Marunouchi-Minamiguchi~Tokyo Big Sight
21
Toyota Drives the Future of Zero Emission Trucking
The Project Portal heavy-duty truck concept generates more than 670 horsepower and 1,325 pound
feet of torque from two Mirai fuel cell stacks, and its estimated driving range is more than 200 miles
Heavy-duty FC Track
22
Toyota Promotes CO2 Emission Reduction and Energy Conservation in Convenience Store Distribution and Operation
Next generation Convenience Stores and Small FC Truck
https://newsroom.toyota.co.jp/en/corporate/22833613.html?padid=ag478_from_kv
23
Toyota Strongly Promotes the Development of Electric Vehicles.
Toyota to Introduce 10 New Electrified Vehicles
in China by 2020
Electric Vehicles
City Commuters
E-Palette Concept
24Contents
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
25
ICSCRM2007(Ohtsu) Keynote Speech
Challenges to reduce cost:
1) Development of Low RonQgd MOSFET 2) Practical use of body diode of MOSFET
26
Development of Trench MOSFET With Ultra Low RonQgd
Deep-P Encapsulated 4H-SiC Trench MOSFETs With Ultra Low RonQgd
(DENSO@ISPSD2018)
Contents
27Development of ultra low RonQgd power MOSFET
[1] DENSO REVOSIC HP https://www.denso.com/jp/ja/products-and-services/industrial-products/sic/
28Development of ultra low RonQgd power MOSFET
29Development of ultra low RonQgd power MOSFET
30Development of ultra low RonQgd power MOSFET
31Development of ultra low RonQgd power MOSFET
32
Stacking Fault Expansion due to Body Diode Operation and the Countermeasures
Contents
33
Gate
Source
Drain
Vg:OFF
H
L
0
Vdd
VRon
Vf
Time chart of synchronous rectifier operation
Vg
Idiode
Vak
Synchronous Rectification
Vg:ON
Synchronous
P
N
Dead TimeDead Time
0
rectification
・In order to reduce conduction losses and device cost,the synchronous rectification is important technology.
・However, the body diode of MOSFET operates during dead time.
34Types of Stacking Faults
・There are Two types of Stacking Faults: Triangle and Bar-shaped.・The expansion of the triangle SFs ended when the shape reached a triangle.・Bar-shaped SFs expand continuously to the end of the active area.⇒ Larger impact on electrical properties.
11-20
35
-6.00
-8.30 -8.55 -8.59-10.0
-8.0
-6.0
-4.0
0.0 10.0 20.0 30.0
VD
S(V
)
Stress Time (min)
VF(Ids=200)
6.809.59
16.04
16.63 16.79
5.0
10.0
15.0
20.0
0.0 10.0 20.0 30.0
VD
S(V
)
Stress Time (min)
VON(Ids=200)
1minInitial 2min 3min 5min 7min 10min 20min 30min
11-20
Stacking Faults Expansion
36
Y. Ebiike, et. al., Mitsubishi Electric Corporation, ISPSD (2018)
Effect of Thickness of Buffer layer to suppress the expansion of SFs
3.3 kV 4H-SiC MOSFETs with various buffer layer thickness has been fabricated in order to investigate the bipolar degradation associated with the expansion of stacking faults.
“Reliability Investigation with Accelerated Body Diode Current Stress for 3.3kV 4H-SiC MOSFETs with Various Buffer Epilayer Thickness”
37
K. Kawahara, et. al., Mitsubishi Electric Corporation, ISPSD (2017)
The purpose of this work is to remove external SBD chips from modules while maintaining device reliability to realize compact high Voltage SiC modules that are free from bipolar degradation.”
Embedded SBDs in planar SiC MOSFETs
“6.5 kV Schottky-Barrier-Diode-Embedded SiC-MOSFET for Compact Full-Unipolar Module”
38
Y. Kobayashi, et. al., Fuji Electric Co. Ltd. and AIST, IEDM (2017)
SWITCH-MOS (SBD-wall integrated trench MOSFET)
"Body-PiN-diode inactivation with low on-resistance achieved by a 1.2 kV-class 4H-SiC SWITCH-MOS"
39SWITCH-MOS (SBD-wall integrated trench MOSFET)
Y. Kobayashi, et. al., Fuji Electric Co. Ltd. and AIST, IEDM (2017)
40Contents
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
1. Vehicle Electrification
- Toyota’s strategy
- Development of electrified vehicles
- Vehicle electrification technologies
- Application of SiC Power Semiconductor Devices on Electrified Vehicles
2. SiC device technologies to expand automotive use
- Development of Trench MOSFET With Ultra Low RonQgd
- Stacking Fault Expansion and the Countermeasures
3. Summary
41Summery
1. Automotive industry is facing profound transformation that comes only once in
100 years.
2.Toyota will strategically develop new values, “Electrification”, “Information” and
“Intelligence”.
3.Toyota believes vehicle electrification is essential to reduce CO2. We accelerate
next-generation electrified vehicles development.
4.In order to expand SiC application on vehicles to contribute toward the reduction
of CO2, we have to reduce total cost of system. Low RonA device development and
improving reliability are key activities for engineers and researches.