Traction inverter system solution accelerates customer development

ST&GIICS

22

Agenda

2

1

2

Traction inverter system solution

3

Key packages

Summary

Traction inverter system solution

4

System overview

4

Traction inverter acting as key role in NEV traction motor control application

Micro Power management SBC SiC MOSFET module Pre driver

Is

ol

at

io

n

Driver

Controller

(Flyback

Contr.)

Gate

driver

ST product line support

System architecture

5

LVBAT

VCUVoltage

regulator

Power supply protectionEMC filter

Can interface

Analog input

SPC58

VDD-HSVDD-LS

SPIINTWDIRST

ERROR

Driver temp*3Phase current UVW

EMCfilter

HVBAT

ASC

SPI

Gate signal

Motor temp

Currentsensor

Over current protection

Voc

Vref

Buffercircuit

Exc+Exc-

S1S2S3S4

HV

conn

ecto

r

U V W

Supplymonitor

VB

STV

CC

VC

C5

VP

RE

RE

G

VCORE

VCC5

VDD30VCC

VCC

BoostBuckLDO

L9396

Flyback

Three-phase bridgeSIC Mosfet & IGBT

Inverter Temp Sensor X3

Tsen

Gate signal

VDD-HSVDD-LS

conn

ector

L9502*6Capacitive Isolation

Phase current UVW

Digital input Air bagASC

VDD30

M

HV

conn

ecto

r

conn

ector

Ain

FSNASC

VH VLML

DISADC_OUT

AD

C_O

UT

DC-LINK Capacitor

DesatVCLBrake

Fault signal

ASCFW

Temp sampling

Analog sampling

SPIIN+IN-

Resolver & Temp sensor

• SPC58NN Micro

• 3 core 200Mhz, 2core lockstep

• ISO26262 – ASILD

• L9396 SBC

• Multiple Power Supply IC

• ASILD

• SiC MOSFET

• 750V 500A SiC MOSFETs Gen 2

• L9502

• Single isolated Gate Driver (6kv) for

Traction inverter with protection ,

diagnostics and communication

• Designed for ISO 26262

compliance

SPC58NN Traction inverter

Automotive ASIL-D

applicationsISO26262

GTM344 SVPWM

SDADC Resolver software

SARADC

High accuracy current sampling ,

temperature sampling and high

voltage sampling

Flash : 6576KB OTA

8X SPI

8X CANFD

Communication between micro and

SBC, micro and Pre Driver , micro

and CAN transceiver ,etc.

Support calibration , CAN Bus

Communication

6

SPC58NN micro for inverter control

FAULT

WDTDIS

Voltage

Monitor

Wake-up

Monitor

IGN

Boost

Controller

9V

300mA

2MHzGNDBST

BSTSW

VBG

VBM

VBST

CPCharge Pump

GN

DA

ResetRESET

GN

D1

Control & Logic

Blocks

SPI

Ctrl/

Status

Reg.

Temp

Mon

Oper

Modes

Fail-

Safe OpFSN

WD

CSN

SDISDO

CLK

Int. analog

3V3 supply

Int. digital

3V3 supply

POR &

Osc.

Buck

6.5V / 7.2V

1000mA

465KHz

BCKSW

VPREREG

LDO VCC5

5.0V

250mA VCC5

LDO VCC

3.3V / 5.0V

100mA VCC

VCCSEL

VCORE

0.8V / 3.3V

1000mA

Buck w/ext FET

500mA

Lin w/ext. FET

VCOREFDBK

Fail Safe

FET

HS predr

Pump Motor FET

HS+LS pre driver

(PWM control)

PD

S

VDBATTWSS / TrackRegRSU0H/L

WS

O0

WS

O1

WS

O2

WS

O3

AI[0..4]

HV Mux +

ADC Converter

Battery protected

switch

VB VB_SW

Decoding

GCORE

VC1 VC2

PD

G

VDSVDG

SCORE

System

Voltages

LS GPO driver

(PWM control)

GPOD0

Voltage

regulation

Motor turn

counter in Low

Power Mode

VC3 VC4

I_CORE_SH

I_CORE_SL

VCORE

PRN

RSU1H/LRSU2H/LRSU3H/L

PR

S

PR

G

PR

I

PD

I PDBATT

7

Automotive multiple power supply IC L9396 SBC

L9396 Traction inverter

LDO (5V, 250mA),

LDO (3.3V / 5V, 100mA),

VCORE (0.8V / 5V +/-2% - µC

core supply, max 1000mA in

switching mode, max 750mA

in linear mode)

Power supply：micro

Analog chip

Pre driver chip

Voltage monitor

WD 2XSystem safety

HS Pre driver Cooling pump control

IGN input Hardware wake-up

SPI Communication (CRC)

Fault output

FSN

Fault diagnosis and fault

protection

Acepack drive

8

Traction inverter for (H)EV, Trucks, Bus

Press FIT connections for high reliable and long lasting connection

SiC-MOSFET based, 750V and 1200V

Pin-fin for direct cooling

Dedicated NTC for each single substrate

Unequalled RDS(on)

ACEPACK DRIVEInternal layout optimized for minimizedstray inductace

High reliability and robustness: Dice sintered to substrate

Different bus bar available to fit welding or screwing connection methods.

AMB substrates for better thermal managment

Incredible high power density

Direct liquid cooled high performance power module

L9502 isolated gate driver

9

• 15 A driver sink/source current capability

• Miller clamp

• Advanced diagnostics and protection

• 10-bit A/D Converter with 2 external inputs

• BRAKE pin with programmable safe state

• 5MHz SPI interface with enhanced safety

• Output flyback voltage 23V (-5V 18V; -8V 15V) on L9502

Single channel isolated gate driver

AEC-Q100 Grade 1

ASIL D systems ready

6kV galvanic isolation

Flyback controller on L9502

IGBT

Is

ol

at

io

n

Driver Controller

(Flyback Contr.)

Gate

driver

Deliverables

• AUTOSAR BSW

• ASIL C safety suit

• Software resolver

• Junction temperature estimation

• Customized design for SiCcontroller with high power density

10

Traction inverter solution

Key Packages

AUTOSAR SW Architecture

12

Name ASIL Description

SCU C SCU realizes the upper layer safety mechanism of MCU such as torque calculation and monitoring, turn-off path control, etc.

ScuCom C This module performs E2E protection for safety-related CAN signals.TCU QM is responsible for the realization of the control functions of the motors.

Cdd_ComCbk QM This module is responsible for transferring security-related message data between BSW_Core0 and ScuCom.

IoSigIf QM The module is responsible for processing low-level digital and analog signals of QM level.

DSC QM DSC module is responsible for responding to diagnostic service requests from CAN

NvmProxy QM NvmProxy is a proxy SWC for accessing NVM modules, which controls NVM reads and writes data based on requests from other

SWCS and returns status information for operations.

DemProxy QM DemProxy is a PROXY SWC that accesses the DEM module, examines error conditions from other WCS, and sets corresponding

diagnostic events.ComProxy QM ComProxy is a proxy SWC for accessing the AUTOSAR

communications stack.SafeIoHwAb C The module is responsible for performing safety-related signal

processing, including processing digital I/O signals, ADC signals,

and etc.Cdd_SBC B The module is responsible for controlling the SBC according to the

upper level request.Cdd_Predrv C The module controlling the Predrv based on the upper-level request

Cdd_ExtAdc C The module obtaining SiC MOS temperature and bus voltage from an external ADC converter chip.

SafeMcal C This module provides part of ASIL C MCU bottom driver to support the upper functions

Bootloader QM Bootloader is responsible for software startup and update.

AUTOSAR BSW overview

13

RTE Adapter

OS

OS

Diag

DCM

Communication

COM NMPduR

CAN LIN

CanTp

CanSm

CanNm

CanIf

LinTp

LinSm

LinNm

LinIf

MCALADC SPI ICU FLS PORT

PWM DIO WDG CAN LIN GPT

MCU ETH IRQ GTM

MSC DMA UART

SDADC I2CFCCU STM IOM SENT

Memory

NVM

MemIf

FEE

EAETH

TcpIp

EthSm

EthTsyn

EthSm

DEM

FIM

Cal

XCP

System

EcuM

ComM

BswM

WdgM

WdgIf

LibE2E

CRC

Microcontroller

IoSigIf Complex

Driver

IoExtDev

L9396

Pwm3ph

LT_Adc

LT_Port

Swc

Swc

L9502

L9966

L9908

TLE9180

APP

BLDC

Functional safety requirements fully available

14

Safety development performed

according to ISO 26262:

⚫ Safety requirements development

⚫ Safety related design

⚫ Safety validation & Verification

development

FSR TSR

HSR SSR

Functional safety ASIL C fully available

15

Shut-off path solution Level 2 torque estimation model Torque estimation result

MCU(Motor Control Unit)

VCU(Vehicle Control Unit )

Receive Command

FSR4:Command Integrity Check

Torque Control and HV Current Control Motor Control Driver

FSR1:Torque Monitor

FSR5:Signal Plausibility Check(Integrity Check)

FSR7:Safe Path Integrity Check

Shut off Switch

System Status Measurement

FSR2:Safe State Management

FSR3:Safe Parameter Calculation(e.g. Actual

Torque)

Status report to VCU

FSR6:Report Actual Torque and Fault

Motor

Resolver

Phase Current

Bus Voltage

Motor Temperature

Position & Speed

PM Temp

Function Requirements Functional Safety Requirements

FSC design

MCUMCU Communication

via BusSet point Control

FOC AlgorithmPower Bridge Control and

Protection

Mode Manager

SF01:MCU Communication via Bus

– E2E

SF02:Determine Phase Current

SF04:Determine HVDC Voltage

SF03:Determine Rotor Position and Speed

SF05:Torque Estimation

SF06:MCU Supervise Torque

SF07:MCU Supervise Speed

SF08:Active Discharge Monitor

SF10:Functional Safety Manager

SF11:Active Safe State

SF12:MCU Supervise Work Mode

SF9:MCU Supervise Power Supply

ModeCmd

TorqueCmd

TorqueEst

HVDC Voltage

MotorSpdCmd

MotorSpd

SpeedFault

TorqueFault

ModeFault

ADFault

SystemPowerFault

ADCmdPhaseCur

Position&Speed

SF14:MCU Supervise Processor

VCU

MOTOR

SystemInforFault

L1 - Function Control [ASIL QM(C)]

L2 - Function Monitoring [ASIL C(C)]

L3 - Controller Monitoring [ASIL C]

SF13:MCU Supervise Component Temperature

TempFault

QMdegradationReq

Basic Funcion

Safe Function

External Module

Safety architecture design

Functional safety V&V available

16

FTA FMEA

FMEDA SW FMEA

DFA

Software resolver overview

17

Motor Axis Angle measurement is very

important for motor efficiency and torque

stability

Resolver sensor of Motor Axis Angle

measurement for higher accuracy and

reliability

>$5

resolver ASIC Micro

exciting

feedback

SPI

A,B,Z

Traditional solution (ASIC):

resolver Micro

exciting

feedback

Cost down solution (software)

PWM

ADC

• Exciting & decoder algorithm implement in Micro

• Minimized discrete external signal condition circuit

Software resolver algorithm overview

18

Static/Dynamic Cos/SinSR overview

Final angle and speedsin, cos data parsing

Software resolver diagnostic and test result

19

Signal Diagnostic Error type

Excitation signal

Output frequency monitoring Excitation signal output error

Output waveform shape monitoring Excitation signal have harmonic

Output amplitude monitoring Ground/power short circuit error

Sin/Cos

Output amplitude monitoring Sin/Cos amplitude error

Output delta amplitude monitoringThe amplitude of Sin and Cos signal are not equal.

Output range check and monitoring Ground/power short circuit error

Angle result Different calculation method comparison Angle calculation error

Test result

Angle accuracy（static & dynamic）： less than 1.15°

Peak sampling algorithm

Integral algorithm

HIL model HIL model

HIL system

❖ HIL - hardware in loop

evaluation result

Software resolver performance evaluation with hardware in loop

20

Software resolver performance evaluation on SPC58NN

21

Motor Test Bench

Bench evaluation:

• traction motor : 50KW,

Junction temperature estimation overview

22

Control board & pre driver

23

Features:

• Combination of SPC58NN Micro and

L9396 SBC constitutes a safety

application

• L9502 supports safety and reliable

Pre-driver for SIC MOSFET L9502X 6

Pre Driver L9502

SPC58

NN

L9396

Control board

Double pulse test

24

L9502 VCLVL

DES

VH

AIN

VO +

VO -

M C

ISEN

TSEN

BRAKE

N C

VL

GN D

GN D

FS

FG

FAULT1

ADC _O UT

IN +

IN - / FAULT2

SCLK

SDO

SDI

N CS

DIS

VDD

GN D

V_UL

NTC+

V_UL

V_U H

NTC-

L9502 VCLVL

DES

VH

AIN

VO +

VO -

M C

ISEN

TSEN

BRAKE

N C

VL

GN D

GN D

FS

FG

FAULT1

ADC _O UT

IN +

IN - / FAULT2

SCLK

SDO

SDI

N CS

DIS

VDD

GN D

V_LL

NTC+

V_LL

V_LH

NTC-

NTC- NTC+

NTC- NTC+

DC+

Phase_U

DC-

VB12 V_UH

V_UL

DPOS

DNEG

CPOS

CNEG

GNDS

SPC58NN

PW M H

PW M L

SBC&

Logic protection circuit

SCLK

SDO

SDI

N CS

VB12 V_LH

V_LL

DPOS

DNEG

CPOS

CNEG

GNDS

ADC 1

ADC 2

Fault_U

Fault_L

Buffer

PW M _O FF

ASC/FW

N CS

DC-LINK CAPACITORBattery

Air core inductance

Hardware

GUI

Schematic

Result

Based on the test data of ST SiC MOSFET, this test helps developers to calculate

system losses

Summary

Summary

26

ST&GIICS can provide a set of product

application solutions

• SPC58NN automotive

microcontroller

• L9396 System Basis Chip

• L9502 Pre-driver

• SiC MOSFET Power module

Design solution Validation report Functional safety Third-party partners

• System architecture

• Requirements analysis

• Hardware schematic

• PCB,BOM

• BSW

• Autosar complex driver

• MCAL

• Double pulse test DATA

• Bench test DATA

• FSR/FSC

• TSR/TSC

• HSR/SSR

• FTA

• DFMEA

• DFA

• FMEDA

• L2&3 design

• GIICS

• Vector

• Etas

• EB

• Greenhills

• Hightec

ST&GIICS can provide a set of traction inverter

solution with feature

• Fulfill AUTOSAR architecture

• Fulfill functional safety ASIL C

• Software resolver

• Junction temperature estimation

• Customized design for SiC controller

ST&GIICS provides valuable application materials for customers

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