Tweeting? Please use hashtag #FTF2011. Freescale on Facebook Tag yourself in photos and upload your own!

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1 Market size and growth Many years of experience Inverter review EV /HEV tear downs Importance of packaging Basic motor control Partnering for quick market access Overview of the Fuji / Freescale High Power IGBTs EV / HEV impact on semiconductor supply The Systems Solution Freescale on Facebook Tag yourself in photos and upload your own! Tweeting? Please use hashtag #FTF2011 1

2 The electrification of the automobile is well under way and accelerating every day. EV / HEV is a fast growing part of automotive electronics. This presentation will provide a mid to high level view of the various types of EV / HEV architectures and the High Power IGBTs that enable the traction motor drive electronics. We ll discuss the new Fuji alliance which enables Freescale to provide the total EV systems solution now including Automotive High Power IGBTs. 2

3 3 Think City Tesla Motors Toyota Prius Chevy Volt Nissan Leaf 3

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5 Kunits forecast Source: S.A.2009 Kunits forecast Source: Valeo Micro Hybrid Mild, Full, Plug-in HEV EV Micro Hybrid Mild-hybrids Full, Plug-in HEV EV Semiconductor SAM (million US$) Source: S.A FSL Application Product Micro Hybrid, Low Voltage Battery Mgt MCU $1 $3 $7 Analog $16 $43 $75 Micro Hybrid Start/Stop MCU $7 $36 $64 Analog+ low votage power $33 $134 $268 Sub Total Micro Hybrid $57 $216 $414 Technologies available within FSL Application Product HEV ( all type, all applications) MCU $25 $104 $152 Analog $31 $125 $188 Power High Voltage $290 $1,256 $1,840 Sub Total HEV $346 $1,485 $2,180 Technologies available within FSL Technologies available through Fuji Alliance (1) Grand Total Micro Hybrid + HEV $403 $1,701 $2,594 (1) Analysts have increased the HEV semiconductor TAM by 10% within one year 5 Toyota Global Sales of Hybrids Top 3M Vehicles (3-/11)

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8 1.21 Giga Watts! 8

9 Collocated EV team in Phoenix with the necessary skills to do: Competitive analysis / existing product evaluation Learning gaining knowledge (general / specific) Providing answers to specific questions (test understanding) IP & patents Product ideas that may / will cross MBGs (Silicon System Solutions) Define new potential products. Provide requirements / prototypes Help with evaluation of potential partners / acquisitions Integrate products / leverage ideas from across the Corporation Provide an environment for rapid prototyping Testing / making business case on new concepts Validating new ideas / inventions Moves Fast 9

10 Features Start/Stop Micro Hybrid Mild Hybrid Full Hybrid Plugin Hybrid Battery EV Start/Stop Regenerative Braking Start/Stop Regenerative Braking Power Assist Start/Stop Regenerative Braking Power Assist Electric Drive Start/Stop Regenerative Braking Power Assist Extended Electric Drive Plugin Grid Start/Stop Regenerative Braking Power Assist Extended Electric Drive Plugin Smart Grid Connectivity ICE Conventional Conventional Downsized Downsized Downsized None Electric Power range (kw) OEM example Tier1s involved Power Device Technology Analog Mixed Signal BMW, PSA, Huyndai, Mazda Valeo, Bosch, Denso, Delphi; Hitachi Low Power (40V) Power supply Networking Hbridge Predriver Ford EcoBoost Valeo, Low Power (65V) Power supply Networking Hbridge Driver Honda, Buick LaCrosse, Bosch, Delphi, Conti, Hitachi, Valeo Low/High Power ( V) Power supply Networking Gate driver Toyota, Ford, GM Volt, Toyota Prius, Denso, Bosch, Conti, Delph, Toyota, Hitachii High Power ( > 400V AC) Power supply Networking Gate driver Bosch, Delta Q, Hitachi, Valeo, Delphi High Power ( > 400V AC) Power supply Networking Gate driver Leaf, Tesla, i- MieV Bosch, Delta Q, Hitachi, Valeo, Delphi High Power ( > 400V AC) Power supply Networking Gate driver MCU range 8 / 16 bit 8 / 16 bit 16 / 32 bit 32-bit 32-bit 32-bit 10

11 BMS Ford Hybrid 2.5L ICE CVT Transmission Dual Motor/Generator Vcc +20V De-saturation & Active clamp PWR 1 of 6 Switches 400+ Volts Micro Controller PWM Temp Driver Controller Gate feedback I limit Position -8V Current sense Over Temp, Over / Under Voltage, Over Current LEM Computation Galvanic Isolation IGBT Gate Control & Fault Detection IGBT Batt Mgnt 11

12 VBATT (12V) Isolation barrier VDC (300V) Power Supply C A N C A N MPC5674F MPC5604P I & O U & I T S M A Power Supply Signal Cond. Fault Latch Udc & I Temp DC DC ISO DC DC ISO DC DC ISO DC DC ISO DC DC ISO DC DC ISO TD350 TD350 TD350 TD350 TD350 TD350 H A L L H A L L H A L L PMSM RES 12

13 65kW Prototype Inverter Being Developed for A Major Auto MFG 13

14 ICE and Electric work to together Regen brakes and CVS transmission Extended city range, reduced emissions vs. gas only Engine charges battery while driving 14

15 Impressive power from electric traction motor Regen brakes capture otherwise wasted energy Recharge at any 120V outlet 3 to 4 Hr. charging using 240V charging station No tailpipe emissions 15

16 Very creative use of planetary gears Electric only traction motor ICE through generator to motor Generator used as motor paralleling traction motor ICE direct drive through the generator. Generator still powers the traction motor 16

17 Supporting Components and Housekeeping Power Conversion CONTROL SECTION MCU Inverter DRIVER SECTION Power dies driver Current Sensor POWER SECTION Power Dies Output Connection Heatsink Substrate Cooling DC/DC +AC/DC Coolant inlet DC/DC Dies Liquid Coolant Charger Dies Coolant outlet 17

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19 Max. output 20kW Max. torque 490Nm Max. velocity 150km/h (when built into 14" tires Mass Approx. 20 kg Reducer type Cycloid reducer Reduction ratio 1/11 Motor type Axial gap type permanent magnet synchronization motor Max. motor speed 15000rpm 19

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21 DC Motor Commutation The stator of a Permanent Magnet DC Motor is composed of two or more permanent magnet pole pieces. The rotor is composed of windings which are connected to a mechanical commutator. In this case the rotor has three pole pairs. 21

22 Brushless DC Motors Basic Structure Permanent magnet (usually ferrite, samarium cobolt, or neodymium iron boron) Requires mechanism to sense rotor position to commutate field properly. This is usually a hall effect sensor array or an encoder i.e.. resolver. 22

23 Six Step BLDC Motor Control (3ph) Voltage applied on two phases only It creates 6 flux vectors Phases are powered based on rotor position This process is called Commutation = on = off Phases voltage 23 Power Stage

24 V Bus PWM1 PWM3 PWM5 PWM2 PWM4 PWM6 Source: Power Electronics, by Ned Mohan, Tore Undeland, and William Robbins, John Wiley & Sons, 1995 Three-phase PWM waveforms and harmonic spectrum. 24

25 PWM1 PWM2 PWM PWM4 PWM5 PWM6 B C A 25

26 Used to create the AC waveforms in the motor but different than PWMs. PWMs treat each phase individually. 2 PWM channels per phase SVM treats the inverter as ONE unit!! ALL 6 switches affected PWMs control the phase voltages offsets between A, B and C SVM controls the Voltage Vector. Benefits: Excellent Torque and speed control Aligns well with digital control algorithms Disadvantages: More micro HP needed * Field Oriented Control (FOC) or Vector Control of a 3-phase AC motor involves imitating the DC motors' operation. All controlled variables are transformed to DC instead of AC via mathematical transformation. The goal is to control torque and flux independently. - 2 null vectors A The inverter can be driven to 8 states. V1 = 001 B V3 = voltage vectors V6 = 110 V4 = 100 V0 = 000 V7 = 111 V2 = 010 V5 = 101 C 1 = Top Switch is on 0 = Bottom Switch is on Peter Pinewski 26

27 What Are We Seeking: Access to auto qualified IGBT, Diode components, modules Influence over IGBT, module roadmap Ability to get to market quickly Profitable cooperation model Security of supply MaxQ Cold plates Fuji IGBTs 600V / 400A Half H Bridge High speed switching Low inductance module structure Potential Partners Semikron Packaging Modules Danfoss Packaging Modules Cooling 27

28 Freescale Semiconductor and Fuji Electric partner to increase efficiency of hybrid electric vehicles Freescale enhances its powertrain portfolio with Fuji Electric IGBT technology to help improve automotive industry s miles per watt AUSTIN, Texas April 11, 2011 Freescale Semiconductor has entered into a strategic alliance with Fuji Electric Co., Ltd. to collaborate on insulated-gate bipolar transistor (IGBT) technology and products for hybrid electric and electric vehicles (HEV and EV). Working with Fuji Electric, Freescale will add high-power IGBT products to its existing portfolio of solutions for electronic powertrain applications, market those products to its automotive customers and define and produce new products based on customer input. IGBTs are currently the largest segment of the market for EV power systems. With the addition of IGBTs to its portfolio, Freescale will offer all of the major electronic components of EV systems, including microcontrollers, analog gate drivers, battery monitoring ICs, power IGBTs and modeling / simulation tools, and software components / tools for motor control development. The IGBT is a high-voltage, high-current switch connected directly to the traction motor in a hybrid electric or electric vehicle. It takes direct current energy from the car s battery and, through the inverter, converts the alternating current control signals into the high-current, high-voltage energy needed to commutate or turn the motor. The IGBT is an ideal motor inverter switch for 35 KW to 85 KW EV motors due to its high efficiency and fast switching. The more efficient the IGBT, the less power is lost to wasted heat, resulting in better mileage or miles per watt (MPW) of energy. Freescale chose Fuji Electric s IGBT technology based on its high-performance characteristics and capability, said Tom Deitrich, senior vice president and general manager of Freescale s RF, Analog and Sensor Group. Coupled with Freescale s automotive portfolio and pedigree, this alliance accelerates our ability to provide automotive customers with higher-efficiency inverter solutions. We are pleased to work with Freescale on IGBT technology and draw on their automotive capability. This alliance will enable our IGBT technology to contribute to the increased efficiency of electric vehicles, said Kuniaki Yanagisawa, executive officer and general manager of Fuji Electric s Electronic Devices Business Headquarters. Freescale is a leader in the automotive semiconductor industry with a successful legacy in powertrain electronics. With its microcontrollers designed into many EV systems today, Freescale is well-positioned to supply customers with IGBTs and other devices that will be critical to the advancement of the electric vehicle. About Fuji Electric Fuji Electric is a leading company providing solutions for Energy and the Environment with its wide variety of products. Power semiconductors, one of its competitive product categories, are essential in the reduction of energy consumption in electric vehicles, industrial machines and home electronic appliances. Further information is available at Fuji Electric Group web site: About Freescale Semiconductor Freescale Semiconductor is a global leader in the design and manufacture of embedded semiconductors for the automotive, consumer, industrial and networking markets. The privately held company is based in Austin, Texas, and has design, research and development, manufacturing and sales operations around the world

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31 Voltage: 650V Current: 400A Voltage: 650V Current: 600A Customer Sampling June Motor Output Up to 65kW Under Development Motor Output Up to 97kW Voltage: 650V Current: 900A Voltage: 1200V Current: 600A Under Planning Motor Output Up to 146kW In Production Motor Output Up to 180kW 31

32 IGBT Diode One 6 Fab Required per 1 Million EVs Cars! 32

33 208 Diodes.42 X.24 Inch on a side Die layout on a 6 Wafer 33

34 Single Motor / Inverter needs 18 IGBTs and 18 diodes 5.05 Cars / 6 IGBT Wafer -> 198, 019 Wafers / Million Cars Cars / 6 Diode Wafer -> 86,580 Wafers / Million Cars 284,599 Total 6 Wafers / Million Cars 6 Fab outputs 750 Wafers / Day 273K /Yr. So What? One 6 Fab per 1 Million Cars! 91 IGBTs.4 X.43 Inch on a side Die layout on a 6 Wafer 34

35 Control Algorithms Leverage Chip Level Features Nice to have Must have Differentiators Control algorithms to exploit Motor specific MCU IP blocks, intelligent gate driver control & local IGBT current sensors; improve efficiency, tighter control loops Comm protocol to interface between gate, sensor, MCU MCU drivers capable to operate and protect the module; auto quality required SW init tools to generate settings within SOA (safe operating area) Models of the Module+Driver (Matlab, Spice) Application examples SW Tools Algorithm Libraries Drivers Control/MCU Board Add Application SW API Algorithm API Drivers On-Chip Peripherals External HW IGBT Drivers IGBT Module Requires ability to communicate bidirectionally across isolation barrier 35

36 How many Giga Watts to get back to the future? Partnering allows Freescale quick access to the Automotive EV / HEV market Fuji has many years of IGBT experience and Freescale has many years of Automotive experience The value add will come as we add IP i.e. packaging, integration, PnP gate drive, etc. Freescale is investigating potential efficiencies for the entire Electronic Traction Motor Inverter system with the goal of achieving the industries best MPW (Miles Per Watt) Session materials will be Look for announcements in the FTF Group on LinkedIn or follow Freescale on Twitter 36

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