48V HEV system introduction and Infineon approach for 48V

He Yaohua ATV AE EDT Richard Zhu ATV system teamHelen XU China xEV Marketing

IADC 2013.10 TongJi University

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China Fleet Fuel Economy & CO2 Target

Stage II Stage III Stage IV (Prediction) Stage V (Prediction)

184g

159g

130g

95g

8L

6.9L

5.0L?

4.1L?

19% ↓

14% ↓

27% ↓

Source: China National Standard Committee, 2012IFCN Marketing, Sep 2012

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Compare of several type of HEV

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The Main Drivers for 48V Systems

What are the drivers for 48V:

12V Start-Stop is good, but limited CO2 reduction

HV-Hybrid is good, but high system costs

48V offers HV-Hybrid-like features for Start-Stop-like costs

CO2 improvement up to 15% and more

System cost target is less than 1000€

and better function/efficiency for some loads

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The Main Enabler for Energy Efficiencyin 48V Systems

Harvest almost all electric energy out of free kinetic vehicle energy, no extra fuel burning

Stop-Start at vehicle standstill

Stop engine and disconnect from drive train while vehicle movement (coasting)

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Operational strategy

operational strategy of current starting systems in NEDC

Operation strategy of 48V starting systems in NEDC

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The Main Enabler for CO2 Reduction in 48V Systems

Coasting, Gliding, Sailing:

Mode 1 Free Gliding (without Losses)Gas pedal 0%, Brake pedal 0%, Speed <20…160km/h,Generator idling, Engine stopped and disconnected

Mode 2 Slowdown Braking (+ Electric Energy Harvesting)Gas pedal 0%, Brake pedal >0% but no friction brake, Generator <10kW, Engine stopped and disconnected

Mode 3 Emergency Braking (+ Electric Energy Harvesting)Gas pedal 0%, Brake pedal >>0% with friction brake, Generator max 10kW, Engine stopped and disconnected

Mode 4 Constant Speed (Low Speed Electric Propulsion)Gas pedal >0%, Brake pedal 0%, keep constant speed,E-motor <10kW, Engine stopped and disconnected

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The Main Enabler for CO2 Reduction in 48V Systems

Electric Energy Recuperation / Harvesting:

Measure 1 Recuperative Generator BrakingToday’s engine coasting brake power is about 5-15kW,emulate brake force only with generator torque

Measure 2 Increased Generator PowerTarget 8-15kW to harvest most kinetic brake energy,not possible with 12V, 48V and 200-300A needed

Measure 3 Tailored Power StorageStore short time 15kW and provide longtime average 0.5kW,not possible with lead acid, 48V Li-Ion or Supercap needed

Measure 4 Longtime Battery Power SupplySupply save vehicle dynamic functions during engine stop,redundant battery and longtime energy needed, 12V + 48V

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48V PowerNet, a German Initiative

48V Core Team and ‘Guests’

Guests

Core

IFX partly participation as semiconductor consultant

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48V Specification LV148Important Statements in the 48V Document

LV148documentavailable

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48V Specification LV148Voltage Levels

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48V PowerNet, Public Announcements

First Anouncement: June 2011: five German car makers announced that they will introduce

48V systems into their cars

„Mit dem neuen 7er wird BMW 48 Volt konsequent in die Serie bringen, zunächst werden Hochstromverbraucher angeschlossen. Sukzessive folgen 12-Volt-Verbraucher.“

48V Specification: Oct. 2011: five German car makers published and adopted the

48V specification, called LV148

48V OEM Announcements: Feb. 2012: BMW, Mr. Frickenstein: 48V comes with the new BMW-7 in 2015 http://www.atzonline.de/Aktuell/Interviews/35/243/Wir-wollen-den-elektrischen-Stromverbrauch-halbieren.html

2012: North America OEM plan 48V plaform.

China: BYD, SAIC, GWM……

Aug. 2012: BYD: adopt 48V battery technologyhttp://auto.hexun.com/2012-08-17/144884839.html

.

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48V PowerNetAnnouncement of German Car Makers June 8,2011

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48V power supply for belt driven starter generator (BSG)

Dr. Alfons Graf

µ-Hybrid / Mild Hybrid 48VSystems

• Starter for cold start (12V)• Inverter for the motor/generator• Battery management Li-ion• 48V Battery disconnect• DC/DC 48V-12V bidirectional

• eBoost (air compressor)• Additional traction motor• Engine fan • Heater cabin, windshield, others • EPS elec. power steering • ARS active roll stability • Climate Compressor • ...

1. Functions

LV Bat.

Transmission

MV Bat. DC/DC

12V Board net

Engine

48V

StarterStarter-Generator

Inverter Control12V

10-15 kW

2-3 kW

2. Main organs (1st phase) 2016

• Start – Stop• Regenerative braking (engine on)• Engine brake emulation (fuel cutoff)• Car sailing / gliding / coasting

• No car launch electrically • No constant speed (engine off)

3. Extension (2nd phase)

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integrated starter generator (ISG)

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48V Motor-Generator (µ-mild-Hybrid) –Functional Schematic

• 48V powernet architecture provides some challenges in the system:

• Separation of 48V and 12 V• Higher voltage generator• DC/DC-configuration and safety• Fulfillment of LV148 of OEMs

(specification of OEMs)

• Functions to be provided:• Start-Stop, <20km/h or higher• Regenerative braking (≈ 10kW)• Electricity without fuel burning• Car Coasting, Gliding, Sailing• Torque Boost (≈ 10kW)• Motor Propulsion (crawl ≈10kW)

or constant speed)

Integrated Motor-Generator

Transmission

48V

8-15 kW

Motor-Generator

Inverter

12V Bat.Pb

Engine

DC/DC

existing 12V powernet

0,2 kWh

Starter orStarter-Generator

48V Bat.Li-Ion OR

2-3 kW

48V

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Functionalities of 48V starting systems

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Starting comfort of 48V starting systems

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12V/48V Car Topology - What to Change

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German OEM Topology Proposal12V/48V Car Topology - What to Change

48V

- 12V MSA Starter - Li-Ion Battery or Super-Cap- 12V 90Ah AGM Battery - 10kW Traction E-Motor - Remove Generator 12V180A - 12kW Motor/Generator Inverter with- Clutch for engine disconnect integrated 12V 200A DC/DC (eta 95%)

120A

M/G10kW

Source: German car manufacturer

Transmission

200A

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48V PowerNet12V Architecture versus 48V Architecture

12VBattery

Gene-rator

G

12V

S

Starter

Jump-start

Loads

Today

12V powernet will be the same (except generator) 48V is an extension to 12V Electric power generation at 48V 12V power supply via DC/DC converter from 48V 12V powernet is not rugged against 48V No access possible to 48V (nomenclature: Terminal 40) Common, but individual Ground (nomenclature: Terminal 41)

DC DC

12VBattery

12V

S

opt.Starter

Jump-start

Loads 48VBattery

M/G

Motor /Generator

opt.PowerLoads

48V

48V Extension

no human access

Safety

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Typical spec for 48V dcdc converter (Hella)

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Topologies for DC/DC Converter 14V/48V

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S D SD

T5 T612V250A

Protection Unit

S D SD

T3 T448V60A

optional Fuse

48V PowerNet DC/DC Converter Concept with Safe Switches

ASIL C needed

- Single failure disconnect- Reverse polarity disconnect

GND

48V SD

SD

L

DC/DC Unit

12V

T2

T1multiple phases in parallel (e.g. 6-12)

Copyright © Infineon Technologies 2012. All rights reserved.Dr. Alfons Graf

48V PowerNet General ECU Partitioning and Block Diagram

LDO12V→5V

µC

e.g.Motor

sensor

12V

CAN/LIN

48V

DC/DC48V→5V

5V

5V

Isol

atio

n

12V GND 48V GND

Leak

age

<1µA

12V Part 48V Part

opt. IN

48V ECU

Individual GND Wires to common Chassis

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48V battery system

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48V PowerNet Market Introduction Scenario 2

48V Scenario 1 48V Scenario 2 SemiconductorApplication

E-Motor Inverter E-Motor Inverter 10KW motor control andactive generator rectification

HV-Battery HV-Battery Li-Ion battery management,balancing and main disconnect

DC/DC 48V/12V (3kW) DC/DC 48V/12V (2kW) >100kHz multiple half-bridges plus safety switches

Engine Fan motor control600W-1000W continuous

Compartment Heater smart switch1-2kW continuous

Other Heaters smart switch200W-400W continuous

EPS el. power steering motor control10W average, 1.5kW peak

ARS active roll stability motor controlxxW average, 1-2kW peak

Climate Compressor motor controlxxW average, 4-5kW peak

maybe some others

Scenario 1: most likely for market introduction >2015

Scenario 2: possible future improvement up to 2020

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MOSFETs OPTIMOS-T, -T2100V and future 80VDPack, D2Pack,TOLL, SuperSO8

B6 Driver IC TLE9180 with SPT9/90

B4 Driver IC TLE6282 with SPT4/90

Smart Switches BTS50085, 6163, 452, 723 …Profet+24V BTT6050 …

DC/DC Regulators TLE6368G2, TLE6389TLF524x1, TLF3xxxx

Li-Ion Battery TLE8000 ‘BALI’ for 13-20 cells, in discussionManagement

LIN, CAN, Flexray regular 12V Portfolio, nothing specific

µC regular 12V Portfolio, support ASIL safety features

48V PowerNet IFX Product Portfolio Overview

1 Production 2 Samples available 3 Application fit to be verified by technology / product release

4 Concept

1

1

1

2

2

3

4

2 1

1

4

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48V PowerNet Applications and Products for Scenario 1

Scenario 1: (possible SOP 2015 and later) Motor-Inverter 8-15kW 48V (Vmax=60V) DC/DC Converter 2-3kW 48V/12V (Vmax=60V) Li-Battery or Supercap Management 48V (Vmax=60V) Battery Disconnect 1000A 48V (Vmax=60V)

Power MOSFET 0.5…2mOhm, 80-100V avalanche, 200-300A DCPower package: D2PACK, TO-leadless

MOSFET Driver ○ 3-phase driver IC Inverter, f=20kHz, Vg_max≈90V, current monitor○ multi half-bridge driver IC DC/DC, f=>100kHz, Vg_max≈90V

Microcontroller 32bit, support ASIL safety features, e.g. Inverter, DC/DC …

Voltage Regulator Buck DC/DC supply, 70V to 5V/3.3V, 200…500mA

CAN, LIN nothing specific, standard 12V portfolio

Battery Management Current sensor 10mA…1000A, V-sensor, T-sensor, Coulomb-meter, SOC-, SOH-, SOF-calculation, Battery balancing IC Vmax=60V,

What 48V products are needed?

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48V PowerNet Applications and Products for Scenario 2

Power MOSFET 1…5mOhm, 80-100V avalanche, 20-50A DCPower package: TO-leadless and D2Pack

MOSFET Driver 3-phase driver IC for Motors, Vg_max≈90V, f=20kHz, current monitor

Power Highside Switch1…10mOhm, ≥70V avalanche, 10-50A DCPower package: TO-leadless

Microcontroller 16-32bit, support ASIL safety features, e.g. EPS, ARS …

Voltage Regulator Buck DC/DC supply, 70V to 5V/3.3V, 100…300mA

CAN, LIN nothing specific, standard 12V portfolio

Scenario 2: (possible SOP 2020 and later) Components of Scenario 1 + additional high power loads:

EPS 1…1.5kW 48V (Vmax=60V) Engine fan 0.6…1kW 48V (Vmax=60V) Heaters, compartment and window, 1…2kW 48V (Vmax=60V) HVAC blower 0.5kW 48V (Vmax=60V) Active chassis control ARS 1…2kW 48V (Vmax=60V)

What 48V products are needed?

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M

Motor /Generator

SPT9 / 90Bridge driver

TLE9180

TricoreTC1782

Supply Tricore

Current sensorLEM converter

2 phase currents

H-bridge48V / 15ATLE6282Excitation

Encoder

4x IPB180N10S4-02per half-bridge

HS-CAN2x

TLE6250DS

48V PowerNet 10kW Motor/Generator Test Platform Partitioning

Motor-Inverter Demonstrator for Scenario 1

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48V Motor-Generator (µHybrid) –Prototype Block Diagram

H-BridgeDriver ICTLE 6282

3-PhaseDriver ICTLE9180

OptiMOS ™-T 100V12x IPB180N10S4-02

Current Sense(Shunt Substitute)2x TLE 4990/98

Rotor Position / Current Sense

Motor-Generator

+48V from Battery

To +12V BatteryH-BridgeDriver ICTLE 6282

DCDCOptiMOS ™-T 100V

2x IPB100N10S3-05

Rotor PositioniGMR SensorTLE 5012

OptiMOS ™-T 100V4x IPD 50N10S3L-16

AUDO MAX32-bit

Microcontroller

e.g. TC1782160 MHz

Flash 1.0/1.5MBRAM 76/112kBSCI, SPI, MSB,ADC, FADC, GPTA, CAN

SPI

2xCAN SCI

MSB

2xADC

FASTADC

GPTA

Battery (KL30)Key (KL15)

DC/DC BuckLDO1 LDO2

Tracker 1LDO3

Tracker 2Voltage MonitoringStand-By Supply

INH&HDLD

Window WatchdogTLE 7368-3„Super-Sonic“

5.5V

/2.5

A5V

/0.8

A3.

3V/0

.7A

1.3V

/x.xA

5V/0

.1A

5V/0

.05A

LIN

ISO

9141

TLE

7259

-2G

E

Powertrain CAN

2 Ch.

CAN

TLE

7250

G

+48V LoadsCurrent Sensor + Battery Monitoring

IC

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48V Semiconductors

48V MOSFET

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48V MOSFET

48V MOSFET

http://www.fairchildsemi.com.cn/about-fairchild/media-center/press-releases/20120403-Infineon-Technologies-Reach.html

飞兆半导体与英飞凌科技就创新型汽车MOSFET H-PSOF TO无铅封装技术达成许可协议

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TLE6389-2GV/-3GVLow-Iq Buck Controller Key Features

Package Application/Block Diagram

Applications• Cluster• Body• Truck

• Output voltage: 5V or adjustable (±3%)• Input voltage VBAT up to 60V• IQ up to 2.3A• Wide ambient operation range: -40°C to 150°C• Current mode control mode• PFM mode at low load current for reduced current

consumption• 100% duty cycle ( low drop out) • Low quiescent current Iq: 130µA at low loads

• Switching frequency 360kHz, synchronizable (250kHz…530kHz)

• Enable and Output under voltage reset• RES thresholds:

• 4.65V (TLE6389-2 V50)• 3.65V (TLE6389-3 V50)

• Internally fixed reset delay time• Voltage comparator (e.g. for Vbatt sensing)• Over-temperature shutdown

PG-DSO-14

DC/DC

Confidential10.06.2010 Page 38

TLE9180 - next generation driver IC Overview 3 phase driver IC for motor driving

applications

Extended operating range Vs 3..60V

Powerful output stage (Imin=0.8A)

High Robustness of motor connections pins of -15 to 90V

Safe SPI (CRC) for configuration and diagnosis

Up to 3 High precise current sense amplifiers

ProSIL features for ISO26262 system certification

Compatible to 5V and 3.3V μCs

Package options:

VQFN48 (7x7) LQFP64 exposed pad

Now proven

-15V