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E3Car - Energy Efficient Electrical Car

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Presentation on theme: "E3Car - Energy Efficient Electrical Car"— Presentation transcript:

1 E3Car - Energy Efficient Electrical Car
Association for European NanoElectronics ActivitieS 4/1/2017 EUROPEAN NANOELECTRONICS FORUM November 2011 Dublin, Ireland E3Car - Energy Efficient Electrical Car E3Car Results Reiner John Infineon Technologies AG, Germany Ovidiu Vermesan SINTEF, Norway Confidential Copyright 2011

2 Outline ENIAC E3Car Objectives / Key facts
E3Car: Components for competitive EV´s Projects and European Funding Platforms E3Car: Vertical/Horizontal project management E3Car Highlights

3 ENIAC E3Car Objectives / Key facts
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. Key facts: 11 European countries 22 Demonstrators 33 Project partners 44 M€ Budget -> 3500 PM -> 147 reports Target + 35% efficiency

4 E3Car: Components for competitive EV´s
Funding E3Car (44M€) 7 EV projects (180M€) E3CAR R&D Pilot MARKET Mass- Manufacturing 2 Mrd € 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%),

5 Projects and European Funding Platforms
National Clusters CASTOR, SmarTop Batman LIB2015 E3Car, MotorBrain IoE, POLLUX

6 E3Car: Vertical/Horizontal project management
„Electrical understanding“ 28 Supply Chains OEM, TIER1 driven Innovations in 4 Application areas Power Conversion Efficiency Temperature Power Management Mileage Efficiency 3500 PMs Power Distribution Efficiency Temperature Flexibility Dynamic Monitoring Harsh environment Sensors Functionality Efficiency Temperature E3Car 8 Work Packages Innovations 22 Demonstrators 3 Electrical Vehicle Domains covered Energy Batteries, super capacitors, range extenders, energy harvesting, grid connections Propulsion Power converters for motor-generators Auxiliary Power supplies only „Automotive understanding“

7 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

8 Energy efficiency and range of operation
E3Car: Achievements in 4 Application areas Solar panel +3 - 5%, 10% 400V IGBT inverter 650V IGBT inverter Efficiency 2. Mileage 3. Temperature 4. Flexibility 5. Functionality 6. Harsh Environment electronics 6. Sensors +9% +15% Starter battery Integration Current-Sensor Energy efficiency and range of operation

9 E3Car: Match of HV technologies and EV
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. IGBT400V devices based on 40mm thin technology Nanoelectronics Technology mapped to EV functional units Match strenghts and limitations of High Voltage (HV) technologies High Voltage CMOS (< 700V) IGBT (400V, 650V, 1200V) BCD (Bipolar/CMOS/DMOS) SOI (Silicon on Insulator) SiC (Silicon Carbide) GaN (Gallium Nitride) Package technologies for high temperature devices Submicron lithography needed to combine complex logic with high voltage driver devices

10 Inverter E3Car Inverter Roadmap: Power Conversion GaN SiC
mCar Car Class A, B, C Truck, Bus High Efficiency, High Temperature Inverter Efficiency + Cost IGBT Technologies SiC GaN Wide Band Gap CEALeti ATLIII-V Lab Basis SiC Infineon Valeo Siemens VBT =400V V V Module IGBT 400 G2+ G2 G1 Power Modul GaN HEMT GaN HEMT: Driver, Switch, Diode >400V, 250°, switching losses 1200V,270°, 150° Automotive reliability +9% Power technology Powermodul + Driver + Control

11 E3Car: IGBT 400V Inverter Modul Inverter IGBT 65u -> 40u
62% 46% 65u -> 40u IGBT Modul Inverter -15% size Pickup 40u Size, parasitics Reduced switching losses -11,7% Reduced conduction losses % reduced thickness and reduced size Costs, performance, power density improved Eff. +9%

12 E3Car: 400V IGBT - 40mm thin wafer

13 E3Car Highlight: IGBT 650V inverter
Modul IBGT Inverter Module 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 All functions in small volume Real time IGBT junction temperature monitoring IGBT State Of Health test at each power up Mounting with springs for good thermal contact over life time Conduction losses reduction Eff. full load Improved Size and Cost (IML) Costs, performance, power density improved

14 E3Car Roadmap of Driver IC-Technologies
Advanced Sensor Integration Sensors Task 7 Sensor integration ST SC20 Sensor materials CNR & G2 SC20 ATMEL AMS ST Efficiency + Cost Driver IC‘s Task 1 & 2 SC6 SC10 SC17 SC18 SC21 G1 SC11 SC19 high integration medium integr. low integr. low voltage medium volt high volt.

15 E3Car: Zero insertion loss current sensor
Hall with Integrated Magnetic Concentrator (HIMC)/up to 30A Size, parasitics Characterization vs. magnetic field DONE Thin (~1um) integrated ferromagnetic material IBGT Low cost standard sputtering deposition Target magnetic properties obtained NEXT STEP: current sensor demonstrator Fluxgate /up to 2A current B 3mm 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) Feedback to the control system

16 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 Output terminals CAN terminals Isolated CAN Output fuse Output inverse-polarity protection SRAM Output power measurement JATAG interface 2 GaN Power Fets Oscillator 3,3V  1,2V 3 phase DC/DC converter Flash 5V  3,3V Main inductance Input EMI-filter Vin 3 to 10V Xilinx FPGA Input inverse-polarity protection Assumptions: No shade  shading footprint - 30% No curvature  Module curvature -16% Grid operation The solution: MPPT on cell level to increase module efficiency Input terminals Peripherals Interior Power Supply DC/DC power stage Controller

17 4/1/2017 17 E3Car: Li-Ion Starter battery
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 17

18 E3Car: Battery Management Systems
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 Battery based one.g 2 modules (block) each 12 cells 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.

19 EVs - A Way of Life - A New Lifestyle
4/1/2017 Enjoy Life! Emissions -> Electrical vehicle vs. combustion vehicle: CO: -99%, HC: -97%, NOx: -92%, CO2: -50%

20 E3Car Culture Interaction, Communication, Information

21 E3Car Environment

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