Automotive Power Shen s2

Emerging Issues in Automotive Power Electronics
John Shen Electrical and Computer Engineering Department University of Michigan-Dearborn johnshen@umich.edu 313-593-5525
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Outlines
Overview of Power Electronics Power Semiconductor Devices Power Electronic Circuits Automotive Case Studies Emerging Issues
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Overview of Power Electronics

What is power electronics? General applications Automotive applications Classification of power processors and converters Interdisciplinary nature of power electronics
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What Is Power Electronics?

Power electronics: to control and process electrical energy efficiently. Power electronics: an enabling technology for computer, communication, industrial control, and automotive technologies.
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General Applications
Power Electronics Applications Computer Communication Consumer Power supplies Battery chargers Refrigeration Lighting & heating Industrial Commercial Utility systems Arospace Military Transportation Automotive
Pumps/compressor Machines & tools Process control Factory automation
HVDC Static var comp. Renewable engr. Energy storage
Aircarft Space shuttle Satelite Military
EV/HEV Battery chargers Load control Trains & Metro
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(Source: Hitachi)
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Voltage and Current Ranges

1000
Power Supplies Traction Automotive
HVDC
Current (Amperes)
100 10
Analog
Lighting Disk Drives
1
Telecommunication Display Drives
0.1 0.01 1
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Digital
10
100
1000
Motor Control
10000
7
Voltage (Volts)
Automotive Applications
E/E Architecture
Multiplex wiring Active power management Telematics Mobile media
Chassis & Safety

Electrical Power steering ABS Traction control Active suspension Airbag ignitor
Body Electronics
Headlamp control HID Power seat Power door Power window Windshield wiper Defrosting/defogging Climate control Instrumentation
Powertrain
Fuel injection Ignition Transmission control Cooling fan control Electronic throttle control Alternator rectifier Voltage regulator Integrated starter generator EV/HEV traction drive Battery charger 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 8
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Military Vehicle Applications

Hybrid electric drivetrains to improve fuel economy Fuel cell: drivetrain and auxiliary power Next generation electrical architectures: 42V and beyond X-by-wire applications Mobile power generation
110V AC 220V AC 12/24/42V DC ..
Central Power Processing Unit
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Classification of Power Converters

AC/DC converters (rectifiers) DC/AC converters (inverters) DC/DC converters AC/AC converters
Input: AC or DC Converter Output: AC or DC
Control
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Interdisciplinary Nature of Power Electronics
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Power Semiconductor Devices

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Ideal power switches Diodes: rectifying, freewheeling, and clamping Power MOSFET: the low voltage load driver IGBT: the high voltage power switch Power ICs and emerging device technologies SiC technology Power losses and thermal management
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 12
Examples of Using Power Switches

Loads: lamps, solenoids, motors, ignition coils, etc.
i + v Load i High-Side Switching

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Load - v +
Low-Side Switching
13
Ideal Power Switches

Block large forward and reverse OFF voltages when OFF (i=0). Conduct large currents when ON (v=0). i=0 Switch between ON and OFF instantaneously. + v Ease of control Rugged and reliable Low EMI during switching
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
ON
i + v=0 -
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Non-Ideal Characteristics: Breakdown Voltage Rating

A real switch can only block a certain amount of voltage (voltage rating) when OFF. The switch will conduct currents if the limit is exceeded (breakdown). Most switches can only block voltages in one direction.
OFF
i + v -
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Non-Ideal Characteristics: Current Rating and Conduction Loss

A real switch always has some resistance and can only conduct a certain amount of current (current rating) when ON. The switch will overheat if the limit is exceeded. Conduction loss: p = i*v=i2*R
ON
i + R v -
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Non-Ideal Characteristics: Switching Speed and Switching Loss

A real switch takes a certain amount of time to switch between ON and OFF states (switching time or switching speed). Switching loss: p(t) = i(t)*v(t)
i ON OFF ON i ON OFF ON
v
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v
Ideal Switch
toff
ton
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Real Switch
Semiconductor Power Devices

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Diode Bipolar Junction Transistor (BJT) Power MOSFET IGBT GTO Thyristor Power ICs and SmartPower devices SiC Devices
Diodes
Diode: a two-terminal uncontrollable device Automotive applications: rectifying (alternator), clamping (transient voltage suppression), and freewheeling (electric drivetrain inverters)
I P N I +
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Reverse (OFF)
V
ON voltage
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Switching Characteristics
Reverse recovery (turn-off) Forward recovery (turn-on) Fast and soft
Real diode current i ON Recovery time trr OFF
Ideal diode current
IRM
Recovery charge Qrr

20
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Zener Diodes
Operating in breakdown mode Used as transient voltage suppressors (TVS) to reduce EMI or provide load dump protection.
+ v -
Circuits
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Power MOSFET
A three-terminal controllable device Driver (or switch) for low-voltage loads Voltage ratings: 30-60V for 14V systems and 75100V for 42V systems
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DC Characteristics
Threshold voltage Vth Drain-source breakdown voltage V(BR)DSS Drain-source resistance RRDSON
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Charge and discharge capacitors No charge storage time
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Safe Operating Area (SOA)
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Avalanche (UIS) Energy Capability

The ability to survive the harsh automotive EMI environment
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MOSFET Device Structure
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Rdson and Current Rating

Current rating is determined by the Rdson and thermal design of the MOSFET. Larger die size=>lower Rdson @ higher cost Trench MOSFET technology provides lower Rdson.
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Insulated Gate Bipolar Transistor (IGBT)

Excellent power switch for HV circuits (>500V) lower conduction loss and high current capability Medium switching speed (<20KHz) Three-terminal device similar to MOSFET Used in ignition coil drivers and EV/HEV traction inverters
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IGBT vs. MOSFET

IGBT: Bipolar (two carriers) Conductivity modulation Medium speed MOSFET: Unipolar (single carrier) Ohmic resistance High speed
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DC Characteristics
Collector (C) iCE Gate (G) + vGE Emitter (E) + vCE -
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DC Comparison: IGBT vs. MOSFET
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Switching Comparison: IGBT vs. MOSFET
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Short Circuit Capability of IGBT

The ability to survive a short-circuit condition for a certain amount of time. Extremely high voltage, current, and power.
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Power ICs & SmartPower Devices

Power ICs or SmartPower devices integrate power devices with control, diagnostic, and protective functions into a single chip or package. Tradeoff between function integration & cost Usually limited to moderate power applications
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Example: Smart High-Side Switch
(Infineon BSP752T) 5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 37
Emerging Power Semiconductors

MOS-gated thyristors (MCT, MCCT, etc.) SiC technology
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SiC: Electrical Properties

Wide bandgap semiconductor material (SiC: 3-3.3eV vs. Si: 1.12 eV) High electric breakdown field (SiC: 1.5-4e6 V/cm vs. Si:2-8e5 V/cm) High carrier mobility High thermal conductivity Specific on-resistance of a SiC device is 1/300th that of an equivalently rated Si device Ideal for high power, high temperature, and high frequency applications (e.g., electric drivetrains)
SiC: Materials
Many polytypes: 6H, 4H, 3C, etc. 4H-SiC for high power devices (higher electron mobility) 50mm 4H- and 6H-SiC wafers available and 75mm SiC wafer capability demonstrated. Micropipe defect is the limiting factor Both bulk and expitaxial SiC wafers needed
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SiC: Power Device Demonstration

Diodes: 2.5-4.5V, Vf of 4V at 1000A/cm2 Power MOSFET: 550V, 25mO-cm2 Thyristor: 900V, Vf of 3.9V at 625A/cm2 SiC BJT, IGBT, low-voltage CMOS devices have also been demonstrated
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SiC: Technical Challenges

Materials: 75-100 mm bulk and epi wafers with low defect density at a reasonable price Oxide interface quality and reliability Ion implantation processes: high temperature implantation and annealing Sheet resistance and contact resistance for p-type SiC doping Companion packaging technology
Analysis of Switch Power Losses: A Simplified Case

PTOTAL = PCONDUCTION + PSWITCHING PCONDUCTION = VON I 0 tON TS
PSWITCHING = PS (ON ) + PS (OFF ) 1 PS (ON ) = Vd I 0t(ON ) f S 2 1 PS (OFF ) = Vd I 0t(OFF ) f S 2
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Analysis of Switch Power Losses: More Realistic Case

Interaction between the main switch and freewheeling diode Nonlinear waveforms Time-varying PWM duty cycles Temperature-dependent device parameters
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Thermal Management
Switch power losses heat up the devices. Maximum junction temperature is the limiting factor on the power handling capability of devices. Selection of appropriate device ratings and proper thermal design are critical steps in power electronics design.
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Electric Loads & Passive Components

Capacitors Inductors Transformers Lamps Solenoids, coils, and relays Motors
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Capacitors
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Inductors
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Transformers
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Lamps
Conventional Halogen lamps are resistive loads. New automotive lighting technologies such as High Intensity Discharge (HID) and LED need special drive circuits. Challenge with 42V systems: A higher bus voltage requires a higher filament resistance to maintain the same power. This results in a thinner and/or longer and less reliable filament. PWM can solve the problem.
Solenoids, coils, and Relays

Solenoids, coils, and relays are inductive loads in nature. Voltage spikes occur when the load currents are interrupted.
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Motors
AC Synchronous Asynchronous 3 -Induction DC Field Winding PM small car motors
SRM Stepper
DC field winding Lundell alternator
PM Brushless DC
Squirrel Cage
Wound Rotor
Shunt
Hybrid
Series
ISG EV/HEV
ISG EV/HEV
regular starters
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An Electromechanical System
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Power Electronic Converters

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Overview Steady state analysis Pulse Width Modulation (PWM) concept High-side, low-side, and H-bridge configurations AC/DC rectifiers DC/DC converters DC/AC inverters Controls of power electronics
Overview of Power Converters

Power electronic circuits move through different topologies as power semiconductor switches open and close Time-domain circuit analysis
Power Flow Input Filter Network Circuits Containing Switches Power Converter
Source
Output Filter Network
Load
Steady State Condition

In power electronic circuits, semiconductor switches constantly change their ON or OFF status. A steady state condition is reached when the circuit waveforms repeat with a time period T.
T
Time
Average Power and RMS Current

Instantaneous power Average power RMS current Power factor
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p (t ) = v(t )i (t ) Pav = 1 T 0 p(t )dt T 1 T
I RMS =
i 2 dt
PF =
Pav = cos I RMSVRMS

57
Steady State Analysis

Exploiting steady state conditions is extremely useful in analyzing power electronic circuits For capacitors: 1 v (t ) = v (t T ) + i ( ) d average current <iC> = 0 C
t C C t T C
vC (t ) = vC (t T ) < iC >=
For inductors: average voltage <vL> = 0
1 t iC ( )d = 0 T t T 1 t vL ( )d L t T
iL (t ) = iL (t T ) + iL (t ) = iL (t T ) < vL >= 1 T
t T
vL ( )d = 0
58
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Pulse Width Modulation (PWM)

In steady-state operation, power switches turn on only for part of each period T. Duty cycle D=TON / T PWM approximates analog waveforms with pulses, allowing more efficient operation of the switches. Low-pass filters are used to smooth the waveforms PWM is the principal converter technique
T + v 5/20/02
TON
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High-Side, Low-Side and H-Bridge Configurations

Vbatt Vbatt Vbatt Lamps, Motors, Solenoids On / Off Control Motors, Bi-directional Solenoids Vbatt
low side
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high side
H-bridge
60
AC/DC Rectifier
Diode circuits analysis: - Assume a state for each diode in the circuit - Simplify and analyze the circuit - Check if the calculated diode voltages or currents being consistent with the assumption
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Single-Phase Bridge Rectifier
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Three-Phase Full-Bridge Rectifier
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DC/DC Converter
Step-down (buck) converter Step-up (boost) converter Step-down/step-up (buck-boost) converter H-bridge converter
DC/DC converters pass energy directly or indirectly (through energy-storage elements) between input and output during part of each cycle
Step-Down (Buck) Converter

vo =v oi vL Vo =<v oi > < vL > < vL >= 0 1 T Vo = v oi ( ) d T 0 T 1 tON = V dd + 0d tON 0 T t = ON Vd = DVd T
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Step-Down (Buck) Converter (Cont)

< v L >= 0 (V dVo )tON + ( Vo )(T tON ) = 0 Vo = tON Vd = DVd T
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Step-Up (Boost) Converter
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Step-Up (Boost) Converter (Cont)

< vL >= 0 V dtON + (V dVo )(T tON ) = 0 1 Vo = Vd 1 D
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Buck-Boost Converter
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Buck-Boost Converter (Cont)

< vL >= 0 V dDT + (Vo )(T DT ) = 0 D Vo = Vd 1 D
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H-Bridge DC/DC Converter
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H-Bridge DC/DC Converter: Bipolar Switching

Vcontrol > vtri: TA+ & TB- ON vcontrol < vtri: TA- & TB+ ON
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H-Bridge DC/DC Converter: Unipolar Switching

Vcontrol > vtri: TA+ ON -vcontrol > vtri: TB+ ON
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DC/DC Converter Applications

Adjustable-speed DC motor drives: electric engine fan, pinch-free power window, smart windshield wiper, etc. 42/14V conversion PWM lighting
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DC/AC Inverter
AC motor drives: EPS or drivetrain Single-phase square-wave inverter Single-phase PWM inverter Three-phase PWM inverter
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Single-Phase (H-Bridge) Inverter
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Switch Control
Valid switch combinations are those that do not short or open the load Only four valid switch states for H-bridge inverters: - TA+ & TB- ON, TA- & TB+OFF => Va=Vdc - TA- & TB+ ON, TA+ & TB- OFF => Va=-Vdc - TA+ & TB+ ON, TA- & TB- OFF => Va=0 - TA- & TB- ON, TA+ & TB+OFF => Va=0
Square-Wave Switching
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PWM Switching (Bipolar)

When vcontrol>vtri, TA+ & TB- ON When vcontrol<vtri, TB+ & TA- ON
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PWM Switching (Unipolar)

When vcontrol>vtri, TA+ ON When -vcontrol>vtri, TB+ ON
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Three-Phase Inverter
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PWM Switching of Three-Phase Inverter
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Control of Power Electronics
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Separation of Time Scales
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PWM Control
PWM is the main technique in power converters
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Automotive Power Electronics: Case Studies

Fuel injector solenoid driver circuits IGBT ignition coil driver circuits Electric power steering systems 42V PowerNet Electric/Hybrid drivetrains
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Fuel Injection System
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Fuel Injector Solenoid Driver Circuit
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Freewheeling Diodes for Protection

V+ V + SUPPLY Inductive Load
Free Wheeling Diode FWD
MCU or CMOS IC PWM Generator Common Common
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Dual-Level Current Control

A large current passes through the inductive solenoid load which quickly opens the valve for fuel release. A lower current is then needed to maintain (or hold) the fuel injector valve until completion.
Fast Recovery Solenoid Driver Circuits

The electromagnetic energy of an inductive load sometimes needs to be cleared quickly. A higher voltage is needed to bring the load current V + SUPPLY to zero faster. V + SUPPLY V = L di/dt
Common
Common
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Fast Recovery Solenoid Driver Circuits (Cont)

VDC 100-130
14 to 53 Volts
Hi-Side Drive
Direct In Combustion Cylinder Fuel Injection Solenoid
1 per Cylinder Boost Converter
Switches: Power Fet"s IGBT's Current Sense
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Ignition Coil Driver Circuits Distributor Systems
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Ignition Coil Driver Circuits Distributorless Systems
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Ignition Coil Driver Circuits Coil-on-Plug (COP) Systems
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IGBT Ignition Driver Circuit

Primary voltage: 350-600V Secondary voltage: 20-40KV
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Inductive Switching
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Detailed Waveforms
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Electric Power Steering Systems

Motor Controller Motor Hydraulic tubes Pump I sense Sense
Valve
hydraulic cylinder
EHPS Electro Hydraulic Power Steering Brushless or Induction Motor drives pump ECU controls motor driving the hydraulic pump.
Motor Controller
EPS, Electric Power Steering Or Direct-Assist Power Steering Electric motor provides assistance ECU controls motor driving the steering column
Steering wheel
electric motor Torque sense
Angle sense
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EHPS and EPS

EHPS
Steering Wheel Steering Column Gear Box Hydraulic Pump Steering Wheel
EPS
Steering Column Gear Box
Wheel Position Angle / Torque
Pressure Sensor
Motor
Wheel Position Angle / Torque
Motor
Power Stage Microcontroller Microcontroller Current Sense Vehicle Speed 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Power Stage Current Sense
Vehicle Speed 5/20/02
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EHPS Power Electronic Circuit

PM MOTOR, SINGLE POWER TRANSISTOR LOW-SIDE PWM DC/DC DRIVE
+12 Ignition
RESET
+ 12V POWER RELAY

Supply Voltage Sense Input
5V REG LVI COP
PM Motor Pressure Sensor Vehicle Speed Sensor Osc Diagnostic Port 5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn MCU
8 bit Core A/D PWM SCI N-FET Drain Voltage Sense Input + FWD PWM Output D
PUMP
Gate Drive
Power Stage
S
G N-FET
com. 101
EPS Power Electronic Circuits
Brushless DC or Induction Motor Drive
Switched Reluctance Motor Drive
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42V PowerNet
100,000
Power Requirement (Watts)
10,000
Growth Rates: 1920-40 6%/yr 1940-70 2%/yr 1970-90 6%/yr Projected 1990-2030: w/o Proplsn. 5%/yr w/ Proplsn. 8%/yr
w/ Propulsion
40 kW 15 kW
wo/ Propulsion
1.8 kW
1,000
100 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030
Year
1900s 6V Systems
1950s 12V Systems
1960s 12/24V Heavy Duty
1970s 12V Systems 5V Electronics
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Ve h ic le Bu s Vo lt a g e (1 4 V S u p p ly)
0 9 11 1 4 .3 16 20
42V Voltage Specification
Min S t a rt Vo lt. Min . Vo lt En g . OFF Ma x Vo lt En g . ON Ma x Cla m p Vo lt .
S e m ic o n d u c to r Re q u ire m e n ts
0 5 14 18 22
Min . Op . Vo lt No m in a l Op . Vo lt Ma x. Op . Vo lt Min Ze n e r Cla m p Vo lt.
Ve h ic le Bu s Vo lt a g e (4 2 V S u p p ly)
0 25 33 43 52 56
Min S t a rt Vo lt. Min Vo lt . En g . OFF Ma x Vo lt En g . ON Ma x Vo lt CLD 5
S e m ic o n d u c to r Re q u ire m e n ts
42
52
58
Min . Op Vo lt No m in a l Op . Vo lt Ma x Op Vo lt Min Ze n e r Cla m p Vo lt
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42V Electrical Architectures
42V
Mot. Alt C1 B1 Str. B2 C2
Electronic Module
42V
B1
Alt.
Str.
C1
Mot
14V
14V
B2 C2
Electronic Module
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42V Integrated Starter Generator (ISG)
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42V/14V DC/DC Converter

S1
42V
PWM Controller
Control Input
S2
14V
Bi-directional conversion (42V <=> 14V) 1-2KW output power

42V Distribution Circuits

ISA
42V Battery 42V Loads
CS51022 14V DC DC CS51022 14V DC DC CS51022 14V DC DC Low Power 5V, 3.3V DC DC
Other 14V Loads (including other lamps)
Right Lamps
Left Lamps
Type C Semiconductors (ECU. Logic, Memory, etc.)
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42V Multiplexing Network and Smart Junction Box (SJB)
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Electric and Hybrid Drivetrains

Bus voltages: 42-300V Power ratings: 5-100KW Motors: induction, BLDC, SRM Power converters: IGBT or MOSFET PWM inverters Control design: P- or DSP-based vector control
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Power Conversion
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Three-Phase PWM Inverter

3 legs / 6 active switches Fixed switching frequency Variable switching duty cycle Both frequency and amplitude of phase voltages controllable KEY: switching sequence of active switches
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Control of AC Motor Drives

Scalar Control (V/f ) Control stator voltage amplitude and frequency Simple implementation Acceptable steady state characteristics Poor transient response Poor transient efficiency Vector Control (Field Oriented ) Control stator voltages and currents represented by vectors Accurate control for both steady state and transient operations High efficiency Complex implementation (DSP and sensors)
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Advanced Vector Control for AC Motor Drives
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Emerging Issues in Automotive Power Electronics

Power losses and efficiency Inverter power module reliability Novel thermal management technology Cost reduction with better power bus regulation EMC concerns 42V or higher voltage electrical architectures
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Power Losses and Conversion Efficiency

Power losses of power switching devices, conversion efficiency, and thermal management are the key design issues for electric drivetrains and other automotive applications (e.g., EPS) New circuit topologies: cascade or soft switching inverters Selecting the right switching devices: a complex design trade-off Peak vs. normal power design dilemma (ratio as high as 10:1): load leveling approach
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Reliability of Power Electronic Modules

A key element toward making electric propulsion more practical is the development of cost-effective, high-efficiency integrated power electronic modules. The reliability of these power modules will be of paramount importance for the success of various EV/HEV concepts due to the critical safety concern for drivers/passengers, stringent quality assurance requirements of vehicles, and extremely harsh underhood automotive environments. In addition, automotive electric drivetrains, due to their wide dynamic range of operation and diverse usage profiles, will likely impose a more stringent reliability requirement on the power modules than any other industrial motor control applications.
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Reliability and Failure Mechanisms

Elevated junction temperatures (150oC max) Thermal-mechanical stress and fatigue: wire bond lift-off, solder joint cracks, Si chip cracks, etc. Vibration Wirebond Connector Contamination Defects
Si Chip Si Chip
Case
Cu Direct Bond Copper Substrate
Baseplate
Solder Joints
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Research in Power Module Reliability

Improving Understanding on Module Reliability Requirements Developing Realistic Reliability Testing Standards and Lifetime Projection Models Enhancing System Diagnostic Capability with Early Warning Fault Detection (embedded diagnostics/prognostics for power electronics)
Drive Cycle & Usage Analysis Inverter Module Power Loss Analysis Inverter Module Thermal Analysis Inverter Module Stress Analysis
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Drive Cycle and Power Loss

CITYNEW Drive Cycle S pe e d Trace
3000
240 220
IS G P owe r Los s Trace
2500
200 180
2000
P owe r Los s (W) 160 140 120 100 80
RP M
1500
1000
500
60
0 0 1000 2000 3000 4000 Time (s ) 5000 6000 7000
40 0 1000 2000 3000 4000 Time (s ) 5000 6000 7000
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Novel Thermal Management

Removal of heat from power electronics is the limiting factor for cost, compactness, and reliability. The disparity between the peak load capability and average load operation of automotive power electronics severely lowers the hardware utilization efficiency and sets a limit on cost reduction and reliability enhancement. Peak power load is typically several times higher than average power load, but only lasts for a short period of time ranging from a few tens of milliseconds to a few seconds.
Phase Change Thermal Management

Transitions between solid, liquid, and gaseous phases typically involve large amounts of energy compared to the specific heat. For example, one gram of water absorbs merely 4.18 joules of heat to increase its temperature by 1oC, but amazingly 2260 joules of heat when vaporized even without any change in temperature. Phase change materials can be used as passive heat moderators in power electronic packages.
Conventional Power Electronics Module
Silicon Case
Proposed Power Electronics Module

Case Silicon Phase Change Heat Moderator
Heat Sink Peak Load Junction Temperature Average Load
Heat Sink
Conventional Power Module Phase Change Power Module
Time
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Improve Power Bus Voltage Regulation to Reduce Cost of Automotive Power Electronics
4 3.5 S pe cific On-Res is tance (mohm-cm2) 3
2.5 NORMALIZED COS T
The ore tic al limit of S ilicon Dis cre te P ower IC
2.5 2 1.5 1 0.5
1.5
0 0 20 40 60 80 Brea kdown Voltage (Volts ) 100 120
15
20
25
30
35 40 45 DC VOLTGAE RATING (V)
50
55
60
65
Power MOSFET Ron vs Voltage Rating

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Capacitor Cost vs Voltage Rating

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Automotive Power Systems
Auto mo tive Po we r S ys te ms 12V Car/Lig ht Truc k 24V He avy Truc k 42V Po w e rNe t
Batte ry Vo ltag e
No minal Ope rating Vo ltag e 14V
Maximum Ope rating Vo ltag e 24V (J ump S ta rt) 34V
12 V
Maximum Dynamic Ove rvo ltag e _
Po we r Ele c tro nic s Vo ltag e Rating 60-40V
24 V
28V
80-60V
36 V
42V
50V
58V (Loa d Dump)
100-75V
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Transients in Automotive Environments

Time Duratio n 200ms to 400ms Caus e Vo ltag e Amplitude <125V Ene rg y Le vel >10J Fre quenc y of Oc c urrenc e Infre que nt
S te ady S tate <320us 200ms 90ms
1ms <50ns
Loa d dump (dis conne ction of ba tte ry while a t high cha rging) Fa ile d voltage re gulator Inductive load s witching Alte rna tor field de ca y Ignition puls e, ba tte ry disconne cte d Harnes s coupling ES D
18V 80-300V -100 to -40V <75V
_ <1J <1J <0.5J
Infre que nt Ofte n Ea ch turn-off <500Hz Infre que nt Ofte n Infre que nt
<200V <15kV
<1J <10mJ
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Proposed Voltage Rating Changes

12V SYSTEMS 24V SYSTEMS
0-60V
VOLTAGE RATING OF POWER ELECTRONICS
0-60V
VOLTAGE RATING OF POWER ELECTRONICS
4-40V TVS CLAMPING VOLTAGE 24-27V
4-60V TVS CLAMPING VOLTAGE 34-37V
6-24V
NORMAL BUS VOLTAGE
6-24V
10-34V
NORMAL BUS VOLTAGE
10-34V
Existing Voltage Rating
Proposed Voltage Rating
Existing Voltage Rating
Proposed Voltage Rating
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Introduction of A New Class of Transient Voltage Suppressors: MOSTVS

Much less variations in clamping voltage than conventional Zener diodes or MOVs over a wide range of current and temperature. Proven power MOSFET technology Provide cost benefits in 12V, 24V, 42V or higher voltage systems
BTB Poly Diodes
D
DC Power Bus
Module 1
Module N
G
Rg
Central Suppressor
Distributed Suppressor
5/20/02
127
Electromagnetic Compatibility Concerns

EMC compliance is a major challenge for automotive power electronic systems Large common-mode inverter currents due to coupling paths to ground through the motor and housing Large di/dt and dv/dt, while minimizing switching losses, generate broadband radiated and conducted emissions. RF characteristics of power semiconductor devices(especially bipolar types) are neither fully investigated nor considered in the EMC consideration. Conducted immunity concerns: load dump, negative transients, etc.
5/20/02
128
Electrical/Electronic Architectures
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129
Electrical Architectures: Power Generation and Distribution

Active power management: multiple power sources, loads, energy storage elements, multiplexing, etc. System stability may become a major concern. Arc fault detection is critical for 42V or higher voltage electrical distribution systems: Distributed current sensor network and DSP to detect arc fault signatures Arc fault detection should be an integral part of electrical architecture design rather than using add-on approach
5/20/02
130
Summary
Power electronics will become more pervasive in automotive systems. Device and circuit technology advances need to be made to meet performance, reliability, and cost targets. Many critical technical challenges and barriers need to be overcome.
5/20/02
131

Automotive Power Shen s2

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Automotive Power Shen s2

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Emerging Issues in Automotive Power Electronics

Overview of Power Electronics

What Is Power Electronics?

Pumps/compressor Machines & tools Process control Factory automation

HVDC Static var comp. Renewable engr. Energy storage

Aircarft Space shuttle Satelite Military

EV/HEV Battery chargers Load control Trains & Metro

Voltage and Current Ranges

Lighting Disk Drives

Chassis & Safety

Military Vehicle Applications

Central Power Processing Unit

Classification of Power Converters

Interdisciplinary Nature of Power Electronics

Power Semiconductor Devices

Examples of Using Power Switches

i + v Load i High-Side Switching

Ideal Power Switches

Non-Ideal Characteristics: Breakdown Voltage Rating

Non-Ideal Characteristics: Current Rating and Conduction Loss

Non-Ideal Characteristics: Switching Speed and Switching Loss

Semiconductor Power Devices

Ideal diode current

Recovery charge Qrr

Safe Operating Area (SOA)

Avalanche (UIS) Energy Capability

MOSFET Device Structure

Rdson and Current Rating

Insulated Gate Bipolar Transistor (IGBT)

IGBT vs. MOSFET

DC Comparison: IGBT vs. MOSFET

Switching Comparison: IGBT vs. MOSFET

Short Circuit Capability of IGBT

Power ICs & SmartPower Devices

Example: Smart High-Side Switch

Emerging Power Semiconductors

SiC: Electrical Properties

SiC: Power Device Demonstration

SiC: Technical Challenges

Analysis of Switch Power Losses: A Simplified Case

PSWITCHING = PS (ON ) + PS (OFF ) 1 PS (ON ) = Vd I 0t(ON ) f S 2 1 PS (OFF ) = Vd I 0t(OFF ) f S 2

Analysis of Switch Power Losses: More Realistic Case

Electric Loads & Passive Components

Solenoids, coils, and Relays

DC field winding Lundell alternator

Power Electronic Converters

Overview of Power Converters

Output Filter Network

Steady State Condition

Average Power and RMS Current

p (t ) = v(t )i (t ) Pav = 1 T 0 p(t )dt T 1 T

Pav = cos I RMSVRMS

Steady State Analysis

For inductors: average voltage <vL> = 0

Pulse Width Modulation (PWM)

High-Side, Low-Side and H-Bridge Configurations

Single-Phase Bridge Rectifier

Three-Phase Full-Bridge Rectifier

Step-Down (Buck) Converter

Step-Down (Buck) Converter (Cont)

Step-Up (Boost) Converter

Step-Up (Boost) Converter (Cont)

Buck-Boost Converter (Cont)