Automotive Auxilliary Motor Drives from Semiconductor Perspective. Dr. D. Graovac, T. Liebetrau, T. Otter

Transcription

1 Automotive Auxilliary otor Drives from Semiconductor Perspective Dr. D. Graovac, T. Liebetrau, T. Otter

2 Agenda 1 Introduction 2 Impact of Control Architecture 3 otor Control Partitionings & System Examples 2

3 Agenda 1 Introduction 2 Impact of Control Architecture 3 otor Control Partitionings & System Examples 3

4 ADAS, CO 2 reduction and adoption of premium features drive semiconductor growth Vehicle production Drivers for semiconductor content per car CO 2 reduction Advanced safety Comfort, premium Courtesy: BW Courtesy: Audi ~2% growth p.a. Further growth in Western Europe, China, and ASEAN Electro-mobility gaining momentum, especially in China Driven by legislation Improvements of ICE (e.g. electric steering, electric pumps and motors) Adoption of EV/HEV Current: crash avoidance Next: assisted driving Future: autonomous driving Premium cars are early adopters of high-end comfort and safety features Trickling down to midrange Q3 FY2016 ~9% p.a. through-cycle growth 4

5 arket growth based on car production growth and increasing number of features Light vehicle production forecast CAGR +3.0% ~+2% +6.1% -2.1% -0.5% +1.6% +2.0% +5.1% ~+3% Source: IHS, September RoW S.Korea Japan N.America Europe China [USD] Total China Europe N. America Japan S. Korea Others Semiconductor value per car by region CAGR +1.6% CAGR +4.1% CAGR +2.1% CAGR +2.3% CAGR +1.0% CAGR +2.1% CAGR +1.5% Source: Strategy Analytics, based on LC production forecasts Q Copyright Infineon Technologies AG All rights reserved. 5

6 arket for electric motors in cars ~3.4 billion electric automotive motors in 2020 Unit CAGR of 5.7% About 102 million cars expected to be produced in 2020 Average 33 motors per car 2.3 billion electric automotive motors in 2012 Approximately 68% were DC brushed and 15% were DC brushless Average 28 motors per car Source: IHS, "Electronic otors in Automotive Applications - World " 6

7 CO2 reduction is not only xev, but also possible through smart electrification of pumps and motors arket trends Infineon s system offering CO 2 reduction through motor electrification Estimated water pump semi content: ~EUR Water pump (cooling) Saves ~4g CO 2 /km Source: Infineon estimates arket forecast for motor electrification [units m] Water pump Vacuum pump Vacuum pump (braking) Saves ~1.5g CO 2 /km icrocontrollers Power Supplies Bridge Drivers Comments Transceivers OSFETs any motors are still on-off state driven while pumps are still belt-driven, thus always on. Smart electrification means pumps and motors are only activated on demand. Source: Strategy Analytics, worldwide market

8 Application trend Smart motor drive 1. Electrical motors replace mechanical solutions Engine cooling fan Electrical coolant pump Park Brake Source: Bosch Product Page EC motor for Diesel thermal management Source: KSPG Automotive, CWA 200 Pierburg product brochure Source: Audi Q3 2. Dynamic DC motor control (PW) improves efficiency, comfort, safety Sunroof Window Lift HVAC flap 3. Brushless DC (BLDC) motors for permanent loads enable higher reliability, less size, improved EC HVAC Blower Fuel Pump Source: Brose Brose IAA 2013, Leightweight BLDC based 8

9 Solution comparison ulti-dimensional criterias Power Voltage Size Weight Noise Efficiency Safety (ISO26262) etc. Application System Supplier Development Resources SW Reuse (microcontroller) Second source etc. Temperature Specific conditions (cold start) Communication Car architecture etc. Environment Component Supplier Technology roadmap Product portfolio Support ability etc. 9

10 Various users Different constraints I want to use my microcontroller platform. I need the cheapest BO. I'm looking for integrated, ready-to-use systems. I do not want to invest into own electronic solution. Purchasing driven I'm a looking for a special feature. I need to balance between development and BO costs. Preferring Turn Key and many more Technology focused 10

11 Drives applications vs. safety requirements Potential ASIL level Small drives Power drives No or low safety requirements ASIL Q ASIL A/B Ventilation flaps Seat adjustment Headlight range adjustment Adaptive light functions HVAC fan, engine cooling fan Fuel pump, oil pump, water pump Window lifts, sunroof, boot lid Windscreen wipers Seat belt pretensioners High safety requirements ASIL C/D Steering wheel lock Power braking Clutch and gearbox actuators Parking brake Stop-start and hybrid drives Electric power steering 11

12 Agenda 1 Introduction 2 Impact of Control Architecture 3 otor Control Partitionings & System Examples 12

13 otor control using remote electronics Long otor Wiring 2phase (DC Brush otor) 3phase (Brushless DC otor) ECU Generic ECU Fuel Pump (DC motor) 13

14 Integrated otor Control Into otor or Gear Housing +12V from Battery PW LIN CAN Input Signals Infineon Demonstrator Board Full Integration into motor housing Series Solution: Integrated Window Lift Source: Küster ADS GmbH 14

15 Examples of Distributed otor Applications HVAC Blower DC, BLDC Engine Cooling DC, BLDC Sun Roof DC, BLDC Front Wiper DC, BLDC Water Pump Oil Pump DC, BLDC Sliding Door Rear Wiper DC DC Trunk, Tail Gate Seat Belt DC Pretensioner DC Fuel Pump DC, BLDC Window Lift DC HVAC Flaps DC, BLDC Benefits of distributed motor intelligence inimized wiring Reduced weight/space Reduced overhead/complexity for options Distributed computing power Improved diagnostics Balanced power dissipation Improved EC performance Standardized and low-cost physical layer/protocol handler 15

16 Example: Door module architecture Centralized electronics central door module ECU Door Lock Window Lift otor Switch Panel Door Lock Window Lift otor Switch Panel Illumination Illumination irror Low wiring effort Rear Door odule Window Light Lock LIN Front Door odule Window Light Lock irror Low scalability Door Lock Window Lift otor Switch Panel Body Control odule CAN Door Window Lock Lift otor Switch Panel Illumination Illumination irror Optimized for full featured door electronics Rear Door odule Window Light LIN Front Door odule Window Light Premium cars Lock Lock irror 16

17 Example: Door module architecture Smart WL architecture otor integrated electronics Door Lock Window Lift otor Switch Panel Door Lock Window Lift otor Switch Panel Illumination Illumination irror Cheap bus system High Scalability Window Light Smart WL Window Light irror Smart WL Higher wiring effort Window Lift otor Switch Panel LIN Body Control odule Window Lift otor Switch Panel Illumination Illumination irror Limited capability for sophisticated options Door Lock Door Lock Window Global car platforms Window Light Smart WL Light irror Smart WL 17

18 Agenda 1 Introduction 2 Impact of Control Architecture 3 otor Control Partitionings & System Examples 18

19 otor control Generic block diagram +12V from Battery Power Supply Position Sensor PW LIN CAN Inter face Discrete Control or icrocontroller Bridge Driver or Relay Driver OSFET or Relay 2-phase (DC Brush otor) or Input Signals Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) 3-phase (Brushless DC otor) - BLDC - 19

20 otor control Various chip integration levels +12V from Battery PW LIN CAN Input Signals Power Supply Inter face Discrete Control Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) Analog Control Bridge Driver or Relay Driver Current easure ment OSFET or Relay Integrated Switch Position Sensor Low development effort Simple design No software Discrete control scheme Integrated Switch with incorporated protection concept Simple unidirectional motor drive (fans, blowers) 20

21 otor control Various chip integration levels +12V from Battery Low development effort PW LIN CAN Input Signals Power Supply Inter face icrocontroller Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) L-Chip (SBC) Bridge Driver or Relay Driver Current easure ment OSFET or Relay Integrated Bridge Position Sensor Free microcontroller choice Software flexibility Integrated motor full-/half-bridge with incorporated protection concept SBC with supply and bus interface Small uni- and bidirectional drives 21

22 Application example HVAC control module Example with 12-fold half-bridge for 6, 11 or 3 motors V DD Vbat 6 motors Non cascaded < 0.8A + 5 motors Cascaded < 0.8A 3 motors High current < 1.6 A Vbat CAN SBC TLE9263 SPI 16/32-bit icrocontroller XC22xx 8-bit icrocontroller XC8xx SPI 12-fold half-bridge driver TLE94112EL LIN HVAC Control odule 22

23 Application example HVAC control module 2/3 Flap System or 1 High Current otor or 2 bi-stable relays 2 motors 3 motors 1 motor Bi-stable Vbat V DD SPI SPI or DI Vbat Parallel < 0.9 A Cascaded < 0.9 A High current < 1.8 A Relays <0.9A CAN SBC TLE /32-bit icrocontroller XC22xx 8-bit icrocontroller XC8xx 4-fold halfbridge driver TLE94x04EP HVAC Control odule / Bi-stable relays 23

24 Electrical parking brake Safe and easy to design with integrated half bridge Generic ECU Source: Brose Product Webpage Electric Parking Brake 24

25 NovalithIC ½-Bridge system in a package P-OSFET (no charge pump) R DS,on-path = 10mΩ 25 C (typ.) BTN8982 Integrated Current Sense Low Emission (EC) Current Limitation and Temperature Protection 25

26 otor control shield with BTN8982 for Arduino DC otor Control Shield for Arduino XC1100 Boot Kit Power Shield for Arduino with 2x BTN8982 Half-Bridge NovalithIC drives Two uni-directional Brushed DC otors, or One bi-directional Brushed DC otor in an H-Bridge configuration Compatible with the Infineon XC1100 Boot Kit Benefits Easy & low cost evaluation & test of Infineon otor Control Solution Professional support from the huge Arduino Open Source Community Software Examples for Arduino Uno and XC1100 Boot-Kit (DAVE ) 26

27 otor control Various chip integration levels +12V from Battery PW LIN CAN Input Signals Power Supply Inter face icrocontroller Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) Bridge Driver or Relay Driver Current easure ment OSFET or Relay Position Sensor High integration level Free microcontroller choice Software flexibility Given U-chip feature set Less current limitation U-Chip All applications 27

28 De-centralized motor control electronics U-chip TLE7184/86 Key Feature Integrated N-Channel OSFET Driver PW interface Voltage supply for µc ain Benefit Well known at customers Optimized system cost for applications with PW interface (without LIN) U - Chip TLE7184/86 28

29 otor control Various chip integration levels +12V from Battery PW LIN CAN Input Signals Power Supply Inter face icrocontroller Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) System-on-Chip Bridge Driver or Relay Driver Current easure ment OSFET or Relay Position Sensor Least internal wiring effort Least components Smallest installation space Given microcontroller Dedicated bus interfaces Less current limitation Designed for specific applications, expanding scope 29

30 Infineon embedded power system on chip solutions Integration & flexibility Standard CPU Smaller footprint System cost reduction Customer icrocontroller Strategy Software igration Effort Reduced Board Space & Component Count 30

31 Infineon embedded power IC: 3rd generation based on Industry standard AR µc Standard µc core Leading edge automotive qualified technology 32-bit AR Cortex T -3 Integrated on Infineon 130nm BCD process Intelligence and Power on a single die 31

32 Infineon embedded power IC TLE986x/TLE987x product family One Product Family for DC and Brushless DC otor Control Further motor applications 32

33 TLE986x and TLE987x key features Inspired by automotive target applications Target Application Fields High-End Sunroof Power Window Lift Advanced H-Bridge DC otor Control Pumps Blowers 3-Phase otor control Key Features AR Cortex -3 processor, 24/40Hz Enables field oriented motor control Scalable Flash memory: 36kB to 128kB Current programmable NFET driver optimized EC behavior Scalable OSFET driver Integrated PW/LIN transceiver compatible with LIN standard 2.x and SAE J2602-supports fast programming via LIN 10-Bit SAR ADC for current sensing synchronized with the internal PW signal generation unit Wide Operating Range, Vs=5.4V to 28V 33

34 TLE4966V-1K for speed & direction Vertical sensing Window Lifter Power Closing Systems Key Features Vertical Hall for In-Plane Sensing sensor can be mounted parallel to magnetic encoder Direction Detection Index Counting 3.5V to 32V operating supply voltage Overvoltage capability up to 42V without external resistor Over current and over temperature protection Low jitter (typ. 0.3us) SD package PG-TSOP6-6-5 ESD (HB): 2kV, 6kV (ISO10605) Automotive qualified K-package: PG-TSOP6 34

35 Index counting with the TLE4966 family 2 Sensing elements are used TLE4966 double Hall sensors combine 2 sensing elements in one sensor Speed 1 Speed 2 Index counting for Power Closing Systems Window Lifter Sunroof Electronic Doors Direction Position t t Trunk Power Closing 35

36 Vertical hall elements in TLE4966V-1K open up new design flexibilities Established Concept using TLE4966K otor Axis Vertical measurement Concept with TLE4966V otor Axis otor Axis S N S N S N TLE4966K Sensitivity Direction Ring agnet PCB Broader Design The new vertical measurement principle: saves space easy mounting of sensor and PCB board allows for more mounting flexibility enables new, compact systems designs Ring agnet S N S N S N Ring agnet New Sensitivity Direction TLE4966V-1K PCB S N S N S N Ring agnet TLE4966V Slim Design New Sensitivity Direction 36 PCB

37 otor control Various chip integration levels +12V from Battery PW LIN CAN Input Signals Power Supply Inter face Discrete Control Supporting Functionality (Position easurement, Switch Panel Inputs, Output Driver) Bridge Driver or Relay Driver Current easure ment OSFET or Relay Position Sensor Additional safety measures High Power Full Discrete Approach Shared functionality Safety Applications 37

38 Electric power steering High safety level using discrete components +12V from Battery Electric Power Steering ECU TLF Safety Power Supply with integ. WD Safety Path Reverse Protection Infineon OptiOS -T2 40V New TO Leadless package 2x igr Sensor TLE 5012 Torque Sensor TLE 4997 TLE 4998 TLE 4906 Differential Hall IC TLE 4941 Steering Torque V CU V Sens V Logic V Tx 32-bit ulti Core CU AURIX TC23xL CAN Transceiver TLE 6251D TLE 7250G 3-Phase Driver IC TLE 7183 TLE 7185 TLE 7189 TLE 9180 Rotor Position/ Current Sense Phase Cut Off Rotor Position igr Sensor TLE 5009 TLE 5012 Current Sense (Shunt Subsitute) TLE 4990 TLE 4997 TLE4998 Steering Angle Speed HS-CAN 38

39 Fail operational actuators for automated/autonomous driving BO to grow by factor 1,3 with Level 3-5 EPS System EPS E-otor EPS Electronic Control Unit DWs -> 20% ZF Lenksysteme Sense Compute Actuate Safe Power Supply 39

40 Summary Diverse Range of technical & economic constraints lead to high variety of solutions and dedicated products Functional integration of electronics into specific devices due to cost and size reduction Integrated motor bridges provide safe solution, simple to use at low development effort Discrete solution using best-in-class OSFETs for larger currents and high safety functionality 40

41 Summary Comparison chart icrocontroller icrocontroller Bridge Driver OSFET Integrated otor Bridge Embedded Power OSFET Current Protection Space Flexibility Benefits Higher Ambient Temperatures Low Development Effort Least Wiring Smallest Space Applications All applications Small uni- and bipolar drives otor Integrated Drives 41

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