Professional Documents
Culture Documents
Automotive Power Shen s2
Automotive Power Shen s2
Automotive Power Shen s2
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
General Applications
Power Electronics Applications Computer Communication Consumer Power supplies Battery chargers Refrigeration Lighting & heating Industrial Commercial Utility systems Arospace Military Transportation Automotive
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
(Source: Hitachi)
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
HVDC
Current (Amperes)
100 10
Analog
1
Telecommunication Display Drives
0.1 0.01 1
5/20/02
Digital
10
100
1000
Motor Control
10000
7
Voltage (Volts)
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Automotive Applications
E/E Architecture
Multiplex wiring Active power management Telematics Mobile media
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
5/20/02
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Control
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 10
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
11
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
Load - v +
Low-Side Switching
13
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
ON
i + v=0 -
14
i + v -
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
15
i + R v -
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
16
v
5/20/02
v
Ideal Switch
toff
ton
17
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Real Switch
Diode Bipolar Junction Transistor (BJT) Power MOSFET IGBT GTO Thyristor Power ICs and SmartPower devices SiC Devices
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 18
Diodes
Diode: a two-terminal uncontrollable device Automotive applications: rectifying (alternator), clamping (transient voltage suppression), and freewheeling (electric drivetrain inverters)
I P N I +
5/20/02 Breakdown Forward (ON)
Reverse (OFF)
V
ON voltage
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
19
Switching Characteristics
Reverse recovery (turn-off) Forward recovery (turn-on) Fast and soft
Real diode current i ON Recovery time trr OFF
IRM
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
Zener Diodes
Operating in breakdown mode Used as transient voltage suppressors (TVS) to reduce EMI or provide load dump protection.
+ v -
Circuits
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
21
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
22
DC Characteristics
Threshold voltage Vth Drain-source breakdown voltage V(BR)DSS Drain-source resistance RRDSON
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
23
Switching Characteristics
Charge and discharge capacitors No charge storage time
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
24
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
25
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
26
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
27
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
28
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
29
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
30
DC Characteristics
Collector (C) iCE Gate (G) + vGE Emitter (E) + vCE -
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
31
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
32
Switching Characteristics
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
33
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
34
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
35
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
36
(Infineon BSP752T) 5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 37
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
38
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
40
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
41
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
43
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
44
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.
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
45
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
46
Capacitors
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
47
Inductors
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
48
Transformers
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
49
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.
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 50
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
51
Motors
AC Synchronous Asynchronous 3 -Induction DC Field Winding PM small car motors
SRM Stepper
PM Brushless DC
Squirrel Cage
Wound Rotor
Shunt
Hybrid
Series
ISG EV/HEV
ISG EV/HEV
regular starters
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
52
An Electromechanical System
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
53
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
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 54
Source
Load
Time
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 56
I RMS =
i 2 dt
PF =
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
vC (t ) = vC (t T ) < iC >=
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
TON
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
59
low side
5/20/02
high side
H-bridge
60
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
61
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
62
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
63
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
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 64
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
65
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
66
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
67
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
68
Buck-Boost Converter
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
69
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
70
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
71
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
72
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
73
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
74
DC/AC Inverter
AC motor drives: EPS or drivetrain Single-phase square-wave inverter Single-phase PWM inverter Three-phase PWM inverter
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
75
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
76
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
5/20/02 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn 77
Square-Wave Switching
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
78
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
79
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
80
Three-Phase Inverter
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
81
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
82
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
83
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
84
PWM Control
PWM is the main technique in power converters
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
85
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
86
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
87
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
88
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
89
Common
Common
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
91
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
92
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
93
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
94
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
95
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
96
Inductive Switching
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
97
Detailed Waveforms
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
98
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
Angle sense
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
99
EPS
Steering Column Gear Box
Pressure Sensor
Motor
Motor
Power Stage Microcontroller Microcontroller Current Sense Vehicle Speed 2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
100
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
102
42V PowerNet
100,000
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
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
103
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
S e m ic o n d u c to r Re q u ire m e n ts
0 5 14 18 22
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
S e m ic o n d u c to r Re q u ire m e n ts
42
52
58
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
104
42V
Mot. Alt C1 B1 Str. B2 C2
Electronic Module
42V
B1
Alt.
Str.
C1
Mot
14V
14V
B2 C2
Electronic Module
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
105
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
106
42V
PWM Controller
Control Input
S2
14V
CS51022 14V DC DC CS51022 14V DC DC CS51022 14V DC DC Low Power 5V, 3.3V DC DC
Right Lamps
Left Lamps
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
108
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
109
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
110
Power Conversion
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
111
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
112
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
114
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
115
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
116
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
117
Case
Baseplate
Solder Joints
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
118
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
119
2500
200 180
2000
P owe r Los s (W) 160 140 120 100 80
RP M
1500
1000
500
60
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
120
Heat Sink
Time
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
122
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
1.5
15
20
25
30
50
55
60
65
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
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
12 V
24 V
28V
80-60V
36 V
42V
50V
100-75V
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
124
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
Infre que nt Ofte n Ea ch turn-off <500Hz Infre que nt Ofte n Infre que nt
<200V <15kV
<1J <10mJ
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
125
0-60V
0-60V
6-24V
6-24V
10-34V
10-34V
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
126
D
DC Power Bus
Module 1
Module N
G
Rg
Central Suppressor
Distributed Suppressor
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
127
128
Electrical/Electronic Architectures
5/20/02
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
129
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
2nd Annual Intelligent Vehicle Systems Symposium Dr. John Shen, University of Michigan-Dearborn
131