NESEM 2013 - Internet of Energy for Electric Mobility Home … · 2013-09-29 · NESEM 2013...

NESEM 2013

Nanoelectronics, embedded systems and effectivness The challenges for electric vehicles

Toulouse 2013-09-25

R. John, Infineon technologies

Agenda

The legal force behind the market

Control, Embedded systems, Safety

Start-Stop 12V & 48V

HEV, PHEV, EV

Novel Power train concept for EV´s

Summary & conclusions

2013-09-11 Copyright © Infineon Technologies AG 2013. All rights reserved.

the legal force convergence

[1] China's target reflects gasoline fleet scenario. If including other fuel types, the target will be lower.

[2] US and Canada light-duty vehicles include light-commercial vehicles.

Sources: http://www.nhtsa.gov/staticfiles/rulemaking/pdf/cafe/Oct2010_Summary_Report.pdf


117 gCO2/km Is about

5 L/100km

170 gCO2/km Is about

7,5 L/100km

95 -110;

CO2 Weighted Average Production

Delta Target: 50g CO2/km ≙ 35% reduction

How to reach the targets?


130g

95g

2013: Back to reality and EV normality

9/29/2013 5

Europe Market volume

9/29/2013 6

Matthias Mühlöder,

Senior Analyst EMEA Powertrain Forecasts

IHS Automotive Conference – Berlin, March 14th

MotorBrain – Market forecast (Yole report, 2011)

9/29/2013 7

Source:

Yole report,

2011

10Mio FEV-HEV

50Mio uHEV

Effectivness for electro mobility

2013-09-11

Combustion Engine

Gasoline Engine

30% CO2 reduction

Diesel Engine

10% CO2 reduction

Electrificatio & Hybridization

Stop/Start + efficient gene.

10% CO2 reduction

Mild Hybrid

20% CO2 reduction

Full Hybrid

30% CO2 reduction

FEV

50% - 100% CO2 reduction

Transmission

MT Switch point assistance

2% CO2 reduction

High efficient AMT or DCT

2% CO2 reduction

Energy management

Energy efficiency

Energy on demand

1.0% CO2 Lightning

1.0% CO2 Infotainment

3.0% CO2 EPS

1.0% CO2 HVAC

1.0% CO2 Fuel pump

3.0% CO2 Engine Cooling

Total

10% CO2 reduction

Air resistance

3% CO2 reduction

Rolling resistance

2% CO2 reduction

Copyright © Infineon Technologies AG 2013. All rights reserved.

Born for EV

1. Light weight

2. Functional integration

3. Passive to active safety

4. Energy management

Contribution from components & systems

Sensors

9/29/2013

9

Source: KEMET

Switching Elements Embedded

systems

Electric Motor

Passive Components

Drive System

Source: QinetiQ

Storage

Source: Infineon

Source: Infineon

Source: Infineon

Source: Siemens

Electric Car

Low Stray inductance

Make it Safe & Secure


Safety Integrity

• Protection against Fraud

• Breach of privacy

• Cyber Attack, War and Terrorism

Security

Electroshock

Car Accident

Fire or Explosion

• Development of functional safety

solutions compliant to safety classes

• ISO26262 ASIL A to D

• Severity

• Exposure

• Controllability

Battery system in aircraft

MultiCore Architecture – Efficiency


Provide 1.5x application performance compared to previous generation

Performance to power consumption ratio increased by 30%

Challenge

No further clock rate increase

New multi-core architecture based on TriCore™ 1.6

Improved core architecture for higher efficiency new TC 1.6E (Efficiency)

Advanced power management techniques, e.g. integrated DC/DC converter

Power dissipation between 1.0-1.5W for triple core system in typical use case

Solution

Powertrain/Safety Microcontroller Roadmap

2013-09-11 Copyright © Infineon Technologies 2013. All rights reserved.

TC1762 66/80MHz, 1M

(X)C164/7 40MHz,0.2M

Typ. Applications

4-6 cyl. GDI/DDI 6-8 cyl. MPI

Hybrid Control High-end E-Drive Chassis Domain

Control

4 cyl. GDI/DDI DCT/high-end ECAT

E-Drive Highest-end Airbag Suspension Systems Vehicle Stability Ctr.

4 cyl. MPI Std. ECAT / AMT

Battery Management

High-end Airbag Active Power Steer. Sensor Clusters 1-2 cyl. MPI Starter-Generator

DC/DC Converter Airbag ABS Power Steering Low-end suspension

Auxiliary Subsystems (e.g. gearstick, tank, …)

& Companion ICs

Production 2011 2012 2013 2014 2015 Outlook

Production Development Concept Idea xx Technology

XC2000

Prem

ium

M

ain

str

eam

B

asic

E

ntr

y

TC1766 80MHz, 1.5M

bare die

TC1766 80MHz, 1.5M

XC2xx4 66MHz, 0.3M

TC1724 133MHz, 1.5M

TC1728 133MHz, 1.5M

TC1746 180MHz, 2.5M

Transmission

Audo-NG/Future/S 90

AUDO MAX

TC1736 80MHz, 1M

TC1767 80/133MHz, 2M

XC2xx8 120MHz, 1M

65 AURIX

TC1748 240 MHz, 4M Transmission

TC1798 300MHz, 4M

XC2xx5 66MHz, 0.5/0.8M

130

CIC310 FlexRay

130

TC1768 133MHz, 3M

bare die

TC1387 150MHz, 3M

TC1796 150MHz, 2M

TC1797 180MHz, 4M

XC2xx7 100MHz, 1.6M

CIC61508 Safety IC

XC8xx HOT

8-32k

TC1791 200MHz, 4M

XC2xx3 40MHz, 0.1M

TC1782 180MHz, 2.5M

TC1793 270MHz, 4M

TC24x 130MHz, 1.5M

TC22x 130MHz, 1M

TC21x 100MHz, 0.5M

TC27x 200MHz, 4M

TC29x 300MHz, 8M

TC290 300MHz, 8M

Bare Die

TC23x 130MHz, 1.5M

TC1784 180MHz, 2.5M

TC26x 200MHz, 2.5M

TC270 200MHz, 4M

Bare Die

TC260 200MHz, 2.5M

Bare Die

CONFIDENTIAL

Innovation in Security product focus


Secure safety MCUs

Current status

Lot of powertrain applications require safety mechanisms.

Numerous reports demonstrate vehicle vulnerability by wireless connections

OEMs getting aware of dependency between safety and security

Concepts to encrypt on-board communication (initial Ethernet; increased attention to CAN)

Proposal

Add Hardware Security Module (HSM) to safety critical MCUs

¬ Field proven IP of Infineon’s chip card & security division

¬ Allows to protect sensitive data, components & IP

TriCore 0

Bridge

Peripherals Peripherals Peripherals

TriCore 1FLASH

SRAM

32-bit

CPU

Fir

ew

all

SRAM

Boot ROM

AES

128

TRNG

Timer

E.g. AURIXTM TC29x/ TC27x

Micro-hybrids Will Have Much Higher Volumes

Source: STRATEGY ANALYTICS

With Infineon 48V system projection

48V

12V

• Conservative estimate of 48 million

stop/start micro hybrids in 2019 by

Strategy Analytics

• 48V first systems will be available in

2015 - 2016.

• 48V Market will really start in 2020.

• Many OEMs and regions in the race

Europe, USA, Korea, China …

• Many Tier1s in the list: Valeo,

Denso, Conti, Bosch, Delphi, Hella,

Mobis, Mando, LG-IT, Samsung EM

…

Micro – Mild Hybrid


Basic Options of µ-Hybrid Systems


• Functions

• Start - Stop

• Limited regenerative braking

• Control electricity generation

• Advanced Modes (solution 3)

• Challenges

• Engine temperature control

• Emissions at Start & Stop

• Control of the 12V board net

• Need of cabin heating

• Need of cabin cooling

• …

1. µHybrid separate starter &

generator

2. µHybrid belt driven starter-

generator

3. µHybrid in the transmission 12V board net

2 kW

LV Bat.

Starter

Rect. Reg. Relay

1

3

5 kW

2 Transmission

Engine

LV Bat.

Starter-

Generator

Inverter

Transmission

Engine

Generator

Starter

Relay

Stabili. Stabilized board net

Stabili. Stabilized board net

12V board net

10-15 kW

Inverter

LV Bat.

Transmission

Motor-

Generator

MV Bat. DC/DC

12V Board net

Engine

48V

Starter Starter-

Generator

Inverter Control 12V

10-15 kW

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

Starter Starter-

Generator

Inverter Control 12V

10-15 kW

2-3 kW

2. Main organs (1st phase) 2016

• Start – Stop

• Regenerative braking (engine on)

• Engine brake emulation

(fuel cutoff + avoid pumping losses)

• Car sailing / gliding / coasting

• No car launch electrically

• No constant speed (engine off)

3. Extension (2nd phase)


End Costumer Price / Efficiency

12V Start-Stop 2kW

12V BSG 5kW

48V BSG 10kW to 15kW

48V BSG + eBoost

48V BSG + TM* FW or RW

End Costumer Price 200€ 500€ 800-1000€ 1300€ 1500€

Fuel Efficiency 3% 5% 10% 15% 15%

TM* Traction Motor, FW Front Wheel drive, RW Rear Wheel drive

3

LV Bat.

Transmission

MV Bat. DC/DC

Engine

48V

10-15 kW Starter-

Generator

Inverter Inverter

LV Bat.

Transmission

Motor-

Generator

MV Bat. DC/DC

12V Board net

Engine

48V

Starter Starter-

Generator

Inverter

Transmission

Trans.

Moto

r

Inv. HV Bat.

12V

board net

En

gin

e Invert

er

DC

/DC

Bat.

Mgn

LV Bat.

Sta

rter-

Genera

tor

4

5

5

3 4 5

Control

12V

Starter

Control 12V

Ctr.

Sta

rte

r

12V

10-15 kW 10-15 kW

10-15 kW

10-15 kW


Plug-in vs. 48V Impact modeling shows benefits for plug-in

Type Saving

CO2

Cost Adder

per Car*

Car Volume*2

p.a.

Total Annual

CO2 Saving*3

Total Invest

€

Invest per g/km

Saving

Plug-in -140 g/km + 5000 € 80k 1,8 Mio. t 400 Mio 35,7 €

Mild Hybrid -14 g/km*1 + 800 € 300k 0,7 Mio. t 240 Mio 57,1 €

set date Copyright © Infineon Technologies AG 2013. All rights reserved.

* Own estimate 1 Based on C-Class (new models 2014) C02 estimate of 140 g/km, saving estimate for mild hybrid -10% 2 Volume ratio of S and C class according IHS production FC (average over several years)

³ Over car life of 160 000 km for the annual sales volume p.a.

The Vehicle Electrification: A Wide Range of Architectures


Parallel Hybrid

20 kW

Tra

nsm

issio

n

Inverter

HV Bat. DC/DC Bat.

Mgn

12V board net LV Bat.

2 kWh

DC/DC

Motor

Engine Serial Hybrid

Trans.

12V board net

LV Bat.

30 kW 50 kW

2 kWh

Engine

Motor

Bat.

Mgn

Gene

Inv-1 Inv-2

DC/

DC HV Bat.

Serial - Parallel Hybrid

Trans.

12V board net

LV Bat.

30 kW 50 kW

2 kWh

Engine

Motor

Bat.

Mgn

Gene

Inv-1 Inv-2

DC/

DC HV Bat. Power Split Hybrid

Trans.

1,3 kWh

Engine

30 kW

50 kW

HV Bat. DC/DC 12V board net

LV Bat. DC/DC Bat.

Mgn

Motor

Generator

Inverter

Inverter

Two Mode Hybrid

2 kWh

30 kW HV Bat. DC/DC 12V board net

LV Bat. DC/DC Bat.

Mgn

Inver.

T

Engine

Mot1

Inver.

Mot2

55-100 kW 55-100 kW

Axial split Hybrid

Transmission

Trans.

2 kWh

Moto

r

Inv. HV Bat.

27 kW

12V

board net

En

gin

e

Invert

er

Sta

rter-

Genera

tor

DC

/DC

Bat.

Mgn

LV Bat.

Plug-in Hybrid

DC/DC 12V board net

LV Bat.

Inver.

T

Engine

Mot1

30 kW HV Bat. DC/DC

Inver.

Mot2 Bat.

Mgn

Charger

AC/DC

Infra- structure

63 kW 54 kW

111 kW 16 kWh ?

Range extender

Trans.

HV Bat. Bat.

Mgn

Charger

AC/DC

Infra-

structure

12V board net

DC/DC LV Bat.

Gene

Inv-1

range extender 20 kW 80 kW

12 kWh

3 to 10 kW

Engine

HV

Accessories

Motor

Inv-2

Battery Electric Vehicle

Motor/

Gene. Trans. HV Bat.

Bat.

Mgn Inv.

Charger

AC/DC

Infra-

structure

12V board net

DC/DC LV Bat.

HV

Accessories

DC

/DC

80 kW 25 kWh

3, 10,

30 kW

125 years of experience building internal

combustion engine vehicles.

20 years of experience building xEV.

Scalability

Motorbrain (efficiency, integration, weight, size, cost)

9/29/2013 20

Inverter 3 Cable 3~ motor

1.Hurdle …cables, boxes….

ECAR-tec 2011 Munich

Evolution

9/29/2013 21

Low stray inductance

Low parasitics

Faster

Cost efficient

http://www.powerguru.org/wordpress/wp-content/uploads/2012/07/Package-outline-SKiM63.jpg

http://www.powerguru.org/wordpress/wp-content/uploads/2012/07/Coefficient-of-thermal-expansion.jpg

Re-think the motor for better semiconductor use

9/29/2013 22

Utilization of more than three-phases enables splitting of the power across a larger

number of inverter legs, enabling semiconductor switches of lower rating.

- lower current per phase

- reduced iron loss

- Intrinsic failsafe machine

- increased torque per rms ampere

- increased power rating

Comparison old 3phase powermodule -motorbrain

9/29/2013 23

800A 3x150= 450A

Feedback: Mandala of power electronics

9/29/2013 24

Bulky power devices

DC-Link capacitor

Cu-Cables

Integration

Separate system

9 Phase machine today

9/29/2013 25

9 Phase machine today

9/29/2013 26

MotorBrain – Cost – economy of scale

9/29/2013 27

Estimated cost savings in EV/HEV by MotorBrain

Most obvious savings for the fully integrated powertrain cost saving

50% housing 100 € Power plugs 150 € 2kg CU cable 30 € 50% cooling cost 100 € Control unit 20 € Passives 10 €

Magnets with rare earth 150 €

total cost saving for integrated Inverter and Motor 560 €

cost saving Batterycapacity (EV 20KWh) by 20% efficiency gain 2.000 € cost saving Battery capacity (HEV 5KWh) by 20% efficiency gain 500 €

total sum for EV 2.560 €

total sum for HEV 1.060 €

Motorbrain top highlights

1. First time worldwide: A fully encapsulated EV power train unit with

multiphase motor without expensive rare earth magnets, integrated

segmented traction Inverter, volume optimized sensors and a multicore

e-Motor control unit, reaching unmatched power density per volume.

2. First time worldwide: Safety concept development in accordance to the

ISO26262 leading to an intrinsic failsafe EV powertrain with a formally

verified absence of single point of failures, and reliable fault-detection

techniques.

3. First time worldwide: Multicore computing power for 9-phase control

covering the 3 times higher control complexity including sensors.

Resulting in better fail safe properties and advanced lockstep safety

functionality.

4. First time worldwide: Smart battery cells allowing monitoring (voltage

and temperature) and cell voltage balancing through a cost-efficient

robust and contactless capacitive differential data transmission.

5. First time worldwide: Powertrain efficiency from plug to wheel for

affordable design of more than 74 % while lowering the cost for a

drivetrain by more than 2.500 € per EV, refer to Table 1. 9/29/2013 28

MotorBrain – Expected semiconductor and

automotive industry market impact

9/29/2013 29

Semiconductor and Automotive Industry impacts

from Intrinsic failsafe powertrain and scalable battery

Semiconductor

market

Leverage on

EV/LEV/HEV

market

Total

Estimated benefits for 5y with total 10Mio EV/LEV/HEV units

for Europe

Benefit

[%]

Benefit

[Bil €]

Benefit

[%]

Benefit

[Bil €]

Benefit

[Bil €]

Overall Cost reduction (EV 7.2%; LEV 7%; HEV 4.2%)

facilitates market growth using more semiconductors content

and (150€ per EV/LEV/HEV unit gain,10MioEV/LEV/HEV)

5% 1,5 15% 1,5 3,0

Time-to-market acceleration

by functional integrated systems and productivity gains (6% *

average 300B€ Semiconductor content per car *40%Production

cost) or car market with 10.000.000 units

10% 0,7 5% 1,5 2,2

Energy efficiency savings

(EV,HEV,LEV average energy cost 0,08€ per km ; 5.000km

yearly mileage) improvement(EV 24,5%, LEV 25%, HEV 24%)

25% 2,8 2,8

Production Productivity gains

on 10.000.000 units based on productions cost 5.000€ per units

enhancement

5% 2,5 2,5

10,5

NESEM 2013 - Internet of Energy for Electric Mobility Home … · 2013-09-29 · NESEM 2013...

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