Benefits of SiC MOSFET technology in powertrain inverter of a Formula E racing car

Transcription

1 Benefits of SiC MOSFET technology in powertrain inverter of a Formula E racing car Dr.-Ing. Felipe Filsecker Application Engineer ROHM Semiconductor GmbH

2 ROHM SiC device development 18 years of experience Fully integrated production system Start of automotive business inch World s first 6inch 3inch Trench SiC MOS 6 inch SiC SBD 2inch mass production mass production Started SiC R&D Acquired SiCrystal SiC SBD / MOS Full SiC Module SiC substrate mass production mass production World s first P. 1

3 Superior material properties of SiC P. 2

4 VGS=18V 16V 14V 12V 10V 8V 6V 4V 2V 0V What benefits can be obtained on system level? Lower resistance Smaller size / higher efficiency Si SiC Higher frequency operation Smaller passive components Si SiC Higher temp. operation Simpler thermal management Si SiC P. 3

5 Inverter Motor CAN Power electronics: a key technology for hybrid and electric vehicles 48 V CAN EMS CAN DC / DC converter 12 V Air compressor Pumps CAN Auxiliaries BMS HV battery LV DC HV DC U V W Steering drive Wireless charger On-board charger High power DC/DC converter Transmission EMS: Energy Management Systems BMS: Battery Management Systems AC charging station Fast charging station (DC) P. 4

6 Range road map of electrical vehicles To increase the e-mobility market the battery range needs to increase Solution from OEMs Batteries get bigger Range gets longer ~ 140 km > 180 km > 250 km > 400 km 24 kwh > 30 kwh > 40 kwh > 70 kwh To reduce charging time Charging power has to get higher 50 kw Fast DC charging on the highway kw 20 kw Charging at commercial places 50 kw 3-6 kw Charging at home or office 11 / 22 kw P. 5

7 Typical single-phase OBC (3.6 / 7.2 kw) AC input (1-3ph) Two-stage PFC Isolated DC/DC HV battery AC DC DC AC DC DC AC DC ROHM SiC devices already in use since 2012 for on-board charger systems Two-stage PFC: Booster diode: 650V SiC SBD P. 6

8 SiC solutions in on-board charging systems PFC SiC SBD (650V/1200V) SiC MOS (650V/30mΩ) Power shunt (2512/3W) DC/DC SiC MOS (650V/30mΩ, 60mΩ) Secondary-side rectifier SiC SBD (650V/1200V) Si Fast Recovery Diode (600V/20A) Package THT: TO220, TO247 SMT: TO252, TO263, TO263-7L P. 7

9 Inverter Motor CAN Power electronics: a key technology for hybrid and electric vehicles 48 V CAN EMS CAN DC / DC converter 12 V Air compressor Pumps CAN Auxiliaries BMS HV battery LV DC HV DC U V W Steering drive Wireless charger On-board charger High power DC/DC converter Transmission EMS: Energy Management Systems BMS: Battery Management Systems AC charging station Fast charging station (DC) P. 8

10 Technical partnership with Venturi Formula E Team Integrating ROHM's full SiC module decreases inverter size and weight 1200-V G-type module P. 9

11 Inverter losses 200kW Si-IGBT-based inverter Power devices : Si IGBT + Si FRD 220kW SiC-MOSFET-based inverter Power devices : SiC MOS + SiC SBD Module: ROHM SiC G type module >400W less per switch at max. power operation P. 10

12 Inverter efficiency 200kW Si-IGBT-based inverter Power devices : Si IGBT + Si FRD >1.3% better efficiency at Max Power operation 220kW SiC-MOSFET-based inverter Power devices : SiC MOS + SiC SBD Module: ROHM SiC G type module 1.1% better maximum efficiency P. 11

13 Traction inverter comparison Key achievements: Volume reduction (ca. 30%), weight reduction (6kg 40%), Higher power density (>1.5x) Inverter Si-IGBT based SiC-MOSFET based Output Power 200kW 220kW Max SW Frequency 16kHz 24kHz Weight 15.0kg 9.1kg Volume 14.3L 10.0L Power Density 14kW/L 22kW/L P. 12

14 Inverter Efficiency [%] Inverter efficiency (at maximum torque operation) Efficiency at maximum torque SiC MOS Max Torque Si IGBT Max Torque Inverter Si-IGBT based SiC-MOSFET based Output Power 200kW 220kW Inverter Efficiency 1* Inverter Efficiency 2** Max SW Frequency 98.0% 99.1% 96.9% 98.2% 16kHz 24kHz Weight 15.0kg 9.1kg Volume 14.3L 10.0L Power Density 14kW/L 22kW/L * Max efficiency ** Max Power Operation Output Power [kw] P. 13

15 Extending cruising distance / Reducing battery capacity Electric vehicle simulation test bench Electric drive system inclunding electric and loss model of the inverter P. 14

16 [N.m] [rpm] [km/h] Extending cruising distance / Reducing battery capacity Conditions 100kW automotive motor, 3-phase PWM mode Switching frequency = 16kHz Battery capacity = 33kWh, battery voltage = 750V SiC module: BSM600D12P3G001 (dv/dt <10kV/us) IGBT module: SKIM459GD12E4 Mission profile: WLTP Class 3b Results Driving distance (Battery charge from 100% to 10%) BSM600D12P3G km +11% SKIM459GD12E km P. 15

17 Economic benefits for SiC vs. Si-based Inverter SiC module + battery reduction cost vs. SiC module cost in 2025 Ref. NEDO: Secondary battery technology development roadmap 2013 Battery cost reduction with SiC power modules for batteries > 40kWh P. 16

18 Summary Big potential for SiC in automotive applications (OBC, DC/DC converters and powertrain inverters) ROHM SiC module is used in 220kW class traction inverter. Inverter achieves efficiency as high as 99.1% with lower volume (30% less), lower weight (40% less), and higher power density (>1.5times higher) than conventional Si IGBT based inverter. A higher efficiency inverter enables battery cost / capacity reduction thanks to the extension of cruising distance (>10%) P. 17

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