Post on 31-Mar-2015
Reiner John Infineon Technologies AG, GermanyOvidiu Vermesan SINTEF, Norway
E3Car - Energy Efficient Electrical Car
E3Car Results
EUROPEAN NANOELECTRONICS FORUM 201115 - 16 November 2011
Dublin, Ireland
Copyright 2011Confidential
Association for European NanoElectronics ActivitieS
Outline
ENIAC E3Car Objectives / Key facts E3Car: Components for competitive EV´s Projects and European Funding Platforms E3Car: Vertical/Horizontal project management E3Car Highlights
ENIAC E3Car Objectives / Key facts
Key facts: 11 European countries 22 Demonstrators 33 Project partners 44 M€ Budget -> 3500 PM -> 147 reports
Objectives: Build a solid nanoelectronics technology base for Europe. Establish reference designs and platforms for electrical vehicles. Develop efficient semiconductor components for the first
industrial generation of electrical vehicles.
Target+ 35% efficiency
E3Car: Components for competitive EV´s
E3CARR&D
Pilot
Mass-Manufacturing
Funding
2 Mrd €
E3Car (44M€) 7 EV projects (180M€)
MARKET
2010 EC Industrial R&D Investment Scoreboard. Five of the top 10 R&D companies in the EU are German, each having substantial R&D-tosales ratios [Volkswagen (5.7%), Siemens (5.6%), Daimler (5.3%), Robert Bosch (9.4%),
Projects and European Funding Platforms
NationalClusters
IoE, POLLUXBatmanLIB2015
CASTOR, SmarTop
E3Car, MotorBrain
E3Car: Vertical/Horizontal project management
E3Car8 Work
Packages
28 SupplyChains
OEM, TIER1
driven
Inn
ovat
ion
s
22 Demonstrators
3 Electrical Vehicle Domains coveredEnergy Batteries, super capacitors, range extenders, energy harvesting, grid connections
Propulsion Power converters for motor-generators
Auxiliary Power supplies only
3500 PMs
Innovations in 4 Application areas
Power ConversionEfficiency
Temperature
Power ManagementMileage
Efficiency
Power DistributionEfficiency
TemperatureFlexibility
Dynamic MonitoringHarsh environment Sensors
FunctionalityEfficiency
Temperature
„Electrical understanding“
„Automotive understanding“
E3Car Highlights
Power conversion E3Car Inverter Roadmap Power conversion domain:
IGBT 400V Semiconductor Technology, IGBT 400 Module and Vehicle Class Micro Scalable Inverter
IGBT 650V Module and Vehicle Class A Scalable Inverter
Smart dynamic monitoring domain: Zero insertion loss current sensor
Power distribution domain: Solar panel integration
Power management domain: Starter battery
Battery management domain: Battery Management Systems matching world wide competition
1. Efficiency
2. Mileage
3. Temperature
4. Flexibility
5. Functionality
6. Harsh Environmentelectronics
6. Sensors
+9%
+15%
+3 - 5%, 10%
400V IGBT inverter650V IGBT inverter
Starter battery
Solar panel
Current-Sensor
Inte
grat
ion
Energy efficiency and range of operation
E3Car: Achievements in 4 Application areas
Build a solid nanoelectronics technology base for Europe. Establish standard designs and platforms for electrical vehicles. Develop efficient semiconductor components for the first industrial
generation of electrical vehicles.
Nanoelectronics Technology mapped to EV functional units
Match strenghts and limitations of
High Voltage (HV) technologiesHigh Voltage CMOS (< 700V)IGBT (400V, 650V, 1200V)BCD (Bipolar/CMOS/DMOS)SOI (Silicon on Insulator)SiC (Silicon Carbide)GaN (Gallium Nitride)Package technologiesfor high temperature devicesSubmicron lithography needed to combine complexlogic with high voltage driverdevices
E3Car: Match of HV technologies and EV
1. IGBT400V devices based on 2. 40mm thin technology
mCar Car Class A, B, C Truck, Bus
High Efficien
cy,
High Tempera
tureInverter
Efficien
cy + Cost
IGBT Tech
nologies
SiC
GaN
Wide Ban
d Gap
CEALeti ATLIII-V Lab
Inverter Basis SiCInfineon
Infineon Valeo Siemens
Inverter
VBT =400V 650V 1200V
Module
IGBT400
G2+
G2
G1
Inverter InverterInverter
PowerModul
GaN HEMT
GaN HEMT: Driver, Switch, Diode
>400V, 250°, switching
losses
1200V,270°,
150°
Automotivereliability
+9%
Module Valeo
Power technology
Powermodul + Driver + Control
Module
E3Car Inverter Roadmap: Power Conversion
E3Car: IGBT 400V Inverter
62%46%
65u -> 40u
1
1,5
2
2,5
3
3,5
4
1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
VC
Es
at (
125°
C)
[V]
@ 7
5A
1st gen. 2nd gen. 3rd gen.
A = 1
A = 0,65
A = 0,44
4th gen.
A = 0,32?
A = 0,40
5th gen.
IGBT Modul Inverter
-15% size
T1
T2T3
T4
2.1
2.2
2.3
2.4
2.5
2.5
2.4
2.3
2.2
2.1
3.1
3.2
3.3
3.4
3.5
3.5
3.4
3.3
3.2
3.1
1.1
1.2 1.3 1.4
1.5 1.6
1.7 1.8
1.9 1.10
Pickup 40u Size, parasitics
Reduced switching losses -11,7%Reduced conduction losses - 10%reduced thickness and reduced size
Inverter
Costs, performance, power density improved
Eff.+9%
E3Car: 400V IGBT - 40mm thin wafer
E3Car Highlight: IGBT 650V inverter
IBGT Modul
Improved Size and Cost (IML)
Costs, performance, power density improved
650V IGBT & Diodes dice
IGBT3/Emcon3 from INFINEON
Trench + Field Stop Technology but with a dice thickness of 110µm (650V)
IML Package from VALEO
Compact solution
Thick copper traces for reduced conduction losses
Conduction losses reduction
Module
Mounting with springs for good thermal contact over life time
All functions in small volume
Real time IGBT junction temperature monitoring
IGBT State Of Health test at each power up
Eff. +2%@ full load
Inverter
low voltage medium volt. high volt.
Advance
d Sensor In
tegration
Efficiency
+ Cost
Driver IC
‘s
Task 1 & 2
&
Sensors
Task 7 SC20
ST
SC20
Sensor materials CNR
ATMEL AMS ST
Sensor integration
high integration medium integr. low integr.
SC11
G2
G1SC6
SC10SC17SC18SC21
SC19
E3Car Roadmap of Driver IC-Technologies
E3Car: Zero insertion loss current sensor
IBGTSize, parasitics
• High measured Fluxgate sensitivity (13V/T)• HIMC Sensitivity improvement 4x-10x, due to the
magnetic concentrator (measured) with respect to a single Hall cell
• Sensor linear range up to 2mT (measured) / 30A (expected)current
B
3mm B
BFeedback to the control system
Thin (~1um) integrated ferromagnetic material
• Low cost standard sputtering deposition
• Target magnetic properties obtained
Hall with Integrated Magnetic Concentrator (HIMC)/up to 30A
Fluxgate/up to 2A
Characterization vs. magnetic field DONE
NEXT STEP: current sensor demonstrator
Assumptions: No shade
shading footprint - 30%No curvature
Module curvature -16%Grid operation
The solution:
MPPT on cell level toincrease module efficiency
E3Car: Smart control Solar Panel Mileage increase with Solar
MAX driving range, 6m2 solar area
Graz, Austria 3419 km/yr
Madrid, Spain 4813 km/yr
Oslo, Norway 2469 km/yr
Interior
Isolated CAN
InputEMI-filter
Input inverse-polarity protection
JATAG interface
3,3V 1,2V
Output fuse
Xilinx FPGA
Oscillator
Output inverse-polarity protection
Output power measurement
Flash
SRAM
Output terminals
CAN terminals
Vin 3 to 10V
Input terminals
3 phase DC/DC converter
2 GaN Power Fets
Main inductance
5V 3,3V
Peripherals
ControllerDC/DC power stage
Power Supply
Phase 3
Phase 2
Phase 1
Phase 3
Phase 2
Phase 1
PWM
A1
A2
B1
B2
RshR1
R2
R3
CTRL
MXDRV
INDE
VOUT
GND solar controller chip
PML D
sup
M
solar module
Development of a near-series starter accumulator (Li-Ion) Operation strategies for complete system
Innovation and Optimization Conductor rails (weight - form - heat build-up) SOC/SOH algorithms Strategies for charging and charge balance Thermo management µElectronic devices, sensors
and power electronic Communication between accumulator
and automobile
E3Car: Li-Ion Starter battery
E3Car: Battery Management Systems
Bat
tery
bas
ed o
ne.g
2 m
odul
es (
bloc
k) e
ach
12 c
ells
ATMEL: The battery management device (Li-ion Battery Monitoring System Basic Chip) is realized on a MPW (Multi-Project Wafer).
AMS: First samples AS8505 available since January 2011, Samples produced on a Multi-Project-Wafer in the FAB in Unterpremstätten Package: QFN 36 pin, Device characterisation started at austriamicrosystems, Results expected until mid of February 2011, Demonstrator build started at FhG, Charactarisation done in Feb
ON Semi analog BMS Analog monitoring circuit, Fabout 15.April on time based on revised schedule. Reason change of concept based on finding requirement and specification refelcting market needs .partitioning, logic FPGA instead og hard coding in the chip. (Multichip approach) -> high flexibility, reprogrammability.
EVs - A Way of Life - A New Lifestyle
Enjoy Life!
Emissions -> Electrical vehicle vs. combustion vehicle:CO: -99%, HC: -97%, NOx: -92%, CO2: -50%
www.e3car.eu
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